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Igor Gorlach

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hakan cetinorge

elshwion elshwion

Ruslan Melentiev

King Abdullah University of Science and Technology (KAUST)

Dr.-Ing. Ingor Baumann

Universiti Teknologi Malaysia - UTM

Universitatea Ovidius Constanta

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Papers by Igor Gorlach

Evaluation of Thermal Stresses in Thermo-abrasive Blasting Nozzles

International Thermal Spray Conference

Thermo-abrasive blasting is a technique, which combines conventional abrasive blasting and HVAF p... more Thermo-abrasive blasting is a technique, which combines conventional abrasive blasting and HVAF processes to prepare surfaces prior coating. Thermo-abrasive blasting has a number of advantages over conventional abrasive blasting as the result of a higher nozzle pressure and heat, which helps to remove impurities from the surface. However, practice showed that the short life of blasting nozzles due to thermal stresses and excessive wear is the biggest drawback of this method. Therefore, the correct nozzle geometry and suitable materials are critical for an efficient operation of thermo-abrasive blasting systems. In this study, computational fluid dynamics and finite element analyses were used to obtain the temperature distribution and to evaluate thermal stresses in nozzle materials. The materials investigated include tungsten carbide-cobalt (WC-6wt.% Co), hot pressed dense silicon carbide (SiC) and SiALON (Si3N4-Al2O3-AlN). The analysis and experiments showed that WC-CO nozzles prod...

Стратегія керування мобільною платформою з всенаправленим приводом

Purpose: Mobile robots are used in many areas of industry and commerce. This paper describes rese... more Purpose: Mobile robots are used in many areas of industry and commerce. This paper describes research on and development of a mobile platform, which is based on the concept of a ball-on-ball balancer, with two electrical drives at an angle of 90° providing a velocity vector in any direction in the horizontal plane. The purpose is to implement an originally novel principle for an omnidirectional mobile platform of very high agility, which is able at any given situation to move immediately in any direction without additional steering movements or steering mechanism. Methodology: In advance of the design and implementation of the control strategy for the mobile device, the method of theoretical modelling of the vehicle’s properties and behaviour was applied. The developed theoretical and numerical dynamic models take into account all the control parameters which allow for the determination of the critical value of angular acceleration of the driving wheel. This is needed to prevent any...

Development of a low-cost automatic guided vehicle (AGV)

Advances in Robotics & Automation, 2018

Development of a reconfigurable pallet system for a robotic cell

MATEC Web of Conferences, 2018

Advanced manufacturing systems allow rapid changes of production processes by means of reconfigur... more Advanced manufacturing systems allow rapid changes of production processes by means of reconfigurability providing mass customisation of products with high productivity, quality and low costs. Reconfigurable Manufacturing Systems (RMS) employ conventional as well as special purpose CNC machines, robots and material handling systems. In customised automated assembly, a number of different workpieces need to be processed simultaneously at various workstations according to their process plans. Therefore, a material handling system is an important part of RMS, whose main task is to provide reliable, accurate and efficient transfer of materials according to the process scheduling, without bottlenecks and stoppages. In this research, a reconfigurable pallet system was developed to facilitate automated robotic assembly for a highly customised production environment. The aim is to design a material handling system for conveying, sorting and processing of parts, which are supplied by robots ...

Enhancing the Accuracy of a CNC Machine using Artificial Neural Networks

Traditionally, geometric errors of CNC machine axes are rectified by means of calibration with su... more Traditionally, geometric errors of CNC machine axes are rectified by means of calibration with subsequent calculations of compensation values applied directly in a machine controller or with the aid of parameterised kinematic error models. The main drawback of these methods is that they require a calibration process, which can be not economically viable for some machine applications. In this research, the proposed approach is based on software compensation with the aid of Artificial Intelligence. The developed methodology allows for compensation of the displacement errors of the linear axes of a special purpose CNC machine using artificial neural networks. Two artificial neural networks, namely the Global Neural Network and the Global Vector Neural Network were applied. The artificial neural networks were derived from the data obtained in the drilling of a large number of holes, in a random sequence, in test plates located in the X-Y plane. The coordinates of the drilled holes were...

Measuring arm calibration

Conventional robot calibration techniques often make use of complex measurement equipment that ca... more Conventional robot calibration techniques often make use of complex measurement equipment that can only be operated by skilled personnel in laboratory environments. This paper presents the calibration of a 6DOF measuring arm with a method that requires no external measurement equipment. The arm is calibrated through the use of a kinematic constraint which allows the collection of training data. This data is then utilized by a genetic algorithm to determine improved Denavit-Hartenberg parameters.

Modelling of a Thermal Spraying Controller Using Matlab/Simulink

There are a number of thermal spraying systems, which are based on air flame processes. Stable co... more There are a number of thermal spraying systems, which are based on air flame processes. Stable control of such systems is difficult to achieve due to the complexity of the combustion process in a small burner and varying process parameters. Therefore, modelling of a system control can provide useful information in optimising the performance of thermal spraying systems. In this research, a simulation model of a thermal spray controller was developed using MATLAB/Simulink software. The model was evaluated by comparing the simulated and actual process parameters. The obtained results indicate that the developed model of system controller provides the main required control parameter, the fuel-air ratio, which corresponds with the optimal value used in the actual control of the thermal spraying system. Keywords—MATLAB/Simulink, modeling, control

Modelling of Boiler Drum Level Control using Flownex Software Environment

WSEAS TRANSACTIONS on SYSTEMS archive, 2019

Power plants are critical in producing the electricity required by modern society. In the majorit... more Power plants are critical in producing the electricity required by modern society. In the majority of countries in the world, including South Africa, the primary sources of electricity are fossil fuel power generation plants. A rapidly increase share of renewable generation places huge demands on conventional coalfired power plants. The inherent variability of renewable energy sources implies that coal-fired plants designed for continuous base load production must now be used for variable load. This can have negative effect on the overall efficiency and life expectancy of these plants. The challenge is, therefore, to balance the network demands with the power station operation, its thermal efficiency, availability and extended plant life expectancy. Hence, the main focus of the current research is on the efficiency of the boiler operation and control through modelling of the boiler subsystems, the processes and simulating various operating conditions, which include fluctuation loads...

Thermal stress evaluation of thermo-blast jet nozzle materials

Development of an affordable Automated Guided Cart for material handling tasks

The use of autonomous vehicles for material handling tasks in industry continues to grow because ... more The use of autonomous vehicles for material handling tasks in industry continues to grow because of higher productivity, improved ergonomics and safety aspects. Despite these advantages, the major drawback of implementing autonomous vehicles is their high cost, which makes it difficult to justify economically the automation of processes. Hence, there is a need to develop an affordable design of autonomous vehicle or Automated Guided Vehicle (AGV). AGVs designs and capabilities vary depending on the complexity of the task, the environment and the level of autonomy. As the AGV market is highly competitive, the designer and the manufacturer need to provide a low-cost solution without compromising the AGV functionality. An Autonomous Guided Cart (AGC) is one of variations of AGVs that provides automation of transporting tasks with a minimum level of control and complexity, and at an affordable cost. In this research, a low-cost AGC was developed specifically for a local automotive manuf...

Application of a Camera for Measuring Robot Position Accuracy

Conventional calibration of industrial robots is carried out with a use of special measurement eq... more Conventional calibration of industrial robots is carried out with a use of special measurement equipment, which is expensive and it also requires skilled personnel to operate. This paper presents a methodology, which utilises a camera to perform measurements of position accuracy of a robot. The experiments were conducted with a KUKA robot and a coupled measuring arm, as well as an in-door GPS (iGPS) in order to compare the results. The accuracy obtained with the camera is in agreement with the robot accuracy, and is better than the error measurement results of the measuring arm and the iGPS. Hence, it is envisaged that this methodology, together with numerical optimisation, can be used for robot calibration.

A Success of University–Industry Partnership

New Trends and Issues Proceedings on Humanities and Social Sciences, 2017

In the fast-changing world, the success of engineering education depends not only on sound engine... more In the fast-changing world, the success of engineering education depends not only on sound engineering knowledge, but also on the ability to apply it in practice from the moment young graduates enter the real industry. In order to be successful in industry, learners need interaction within the real industrial environment from the beginning of their studies. The importance of close links between engineering educational programmes and industry is shown in the example of industry–university collaboration between the Nelson Mandela Metropolitan University (NMMU) and General Motors South Africa (GMSA). The local automotive industry and GMSA, in particular, have been supporting the engineering programmes at NMMU for decades. However, with the establishment of a bachelor degree programme in mechatronics in 2005, GMSA decided to play an even more prominent role, as this was the first such degree programme in the Eastern Cape. This initiative has resulted in the establishment of the Chair of...

Modelling of boiler fireside control in flownex software environment

2015 Pattern Recognition Association of South Africa and Robotics and Mechatronics International Conference (PRASA-RobMech), 2015

With the influx of renewable generation technology and the constraints placed on the grid due to ... more With the influx of renewable generation technology and the constraints placed on the grid due to unplanned maintenance on aging power stations, coal fired stations designed for continuous base load production have to fulfil the role of frequency support. With the high inertia of the coal fired power stations, the dynamic operating philosophy of frequency support will impact negatively on the overall efficiency and life expectancy of these plants. The solution proposed is to develop a computational model of the boiler controllers capable of optimising boiler fireside control loops and control philosophies. The model will enable engineers to test and optimize various control parameters. The model will also be a safe environment for testing transient scenarios, such as the loss of a draught group or a multiple mill trip.

Development of a Controller for a Reconfigurable Manufacturing Cell

Reconfigurable Manufacturing Systems (RMSs) are widely used in modern production. The important f... more Reconfigurable Manufacturing Systems (RMSs) are widely used in modern production. The important features of RMSs, such as modularity, integrability and diagnosability, require open-architecture controllers. However, sub-systems from different vendors often use different communication protocols and interfaces. Hence, a RMS controller must be capable to overcome this drawback and allow easy control and integration of various types of controllers, devices and machines. This paper presents the development of a personal computer based cell controller, which is used for the control of a reconfigurable manufacturing cell. The SCADA control platform, developed with Movicon™ software, uses standard and special communication protocols

A new method for thermal spraying of Zn–Al coatings

Thin Solid Films, 2009

Abstract This paper presents the development of the thermal spraying system built on the principl... more Abstract This paper presents the development of the thermal spraying system built on the principles of the high velocity air flame (HVAF) process. HVAF sprayed coatings showed considerably higher bond strength than coatings obtained by the conventional methods, indicating the advantage of this method in areas where the adhesion strength is critically important. The highly dense structure of the coating obtained with HVAF eliminates a need for a top paint coat, which is typically applied on metal sprayed coatings to extend service life. The thermal sprayed coatings were characterized by the standard techniques, such as light microscopy, scanning electron microscopy with energy-dispersive spectroscopy, X-ray diffraction, salt spray and bond strength tests. The results show that thermal sprayed coatings have a dense structure, low presence of oxides and high resistance to corrosion. High spray rate and good coating quality make the HVAF thermal spray method a viable alternative to the conventional thermal spraying technologies, such as Wire Flame and Twin-Wire Arc.

Progress in Thermo-Abrasive Blasting Systems

The South African Journal of Industrial Engineering, 2012

A Comparative Study of Automation Strategies at Volkswagen in Germany and South Africa

The South African Journal of Industrial Engineering, 2012

The final car assembly lines at Volkswagen's production sites in Germany and South Africa are ana... more The final car assembly lines at Volkswagen's production sites in Germany and South Africa are analysed to determine the best automation level based on cost, productivity, quality, and flexibility for a plant location. The methodology used is proposed by the Fraunhofer Institute. The final assembly processes are analysed and classified according to the automation level. The operations are evaluated at every level of automation based on information from existing factories. If the best levels of automation for all the parameters correspond, the optimal level of automation for a plant is reached. Otherwise, improvements and/or additional considerations are required to optimise the automation level. The result of the analysis indicates that the highest automation level is not necessarily the best in terms of cost and quality, and some de-automation is required. The analysis also shows that a low automation level can result in poor product quality and low productivity. The best automation strategy should be based on the analysis of all the aspects of the process in the local context.

Validation of iGPS as an external measurement system for cooperative robot positioning

The International Journal of Advanced Manufacturing Technology, 2012

External metrology systems are increasingly being used in modern manufacturing to improve the acc... more External metrology systems are increasingly being used in modern manufacturing to improve the accuracy of industrial robots. In this paper, the problem of achieving absolute accuracy in the positioning and movement of cooperating robots is addressed using the indoor GPS (iGPS) technology as an external position measurement system for real-time feedback and control. This metrology system is presented as an introduction to the iGPS-based 3D Pose Detector and a new concept using generalised measurement systems inspired by iGPS. Attached to the robot end-effectors, the receivers allow coordinate frame measurements to provide spatial information on the robot poses in six degrees of freedom. Experimental results show a strong correspondence between iGPS measurements of cooperating robot end-effector positioning and the control measurements obtained from a double ballbar. Ballbar measurements are further used to determine the relative accuracy between state-of-the-art cooperating manipulators. The iGPS system is validated as an external measurement system using a ballbar device, and its use in the external control of basic robotic tasks is demonstrated. The predicted accuracy achievable for the robots when being controlled or compensated is

Development of an Automated Guided Vehicle Controller Using a Systems Engineering Approach

SOUTH AFRICAN JOURNAL OF INDUSTRIAL ENGINEERING

Automated guided vehicles (AGVs) are widely used for transporting materials in industry and comme... more Automated guided vehicles (AGVs) are widely used for transporting materials in industry and commerce. In this research, an intelligent AGV-based material-handling system was developed using a modelbased systems engineering (MBSE) approach. The core of the AGV, the controller, was designed in the system modelling language environment using Visual Paradigm software, and then implemented in the hardware. As the result, the AGV's complex tasks of material handling, navigation, and communication were successfully accomplished and tested in the real industrial environment. The developed AGV is capable of towing trolleys with a weight of up to 200kg at walking speed. The AGV can be incorporated into an intelligent material-handling system with multiple autonomous vehicles and work stations, thus providing flexibility and reconfigurability for the whole manufacturing system. Ergonomic and safety aspects were also considered in the design of the AGV. A comprehensive safety system that is compliant with industrial standards was implemented.

Navigation and locomotion of a low-cost Automated Guided Cart

2015 Pattern Recognition Association of South Africa and Robotics and Mechatronics International Conference (PRASA-RobMech), 2015

Evaluation of Thermal Stresses in Thermo-abrasive Blasting Nozzles

International Thermal Spray Conference

Thermo-abrasive blasting is a technique, which combines conventional abrasive blasting and HVAF p... more Thermo-abrasive blasting is a technique, which combines conventional abrasive blasting and HVAF processes to prepare surfaces prior coating. Thermo-abrasive blasting has a number of advantages over conventional abrasive blasting as the result of a higher nozzle pressure and heat, which helps to remove impurities from the surface. However, practice showed that the short life of blasting nozzles due to thermal stresses and excessive wear is the biggest drawback of this method. Therefore, the correct nozzle geometry and suitable materials are critical for an efficient operation of thermo-abrasive blasting systems. In this study, computational fluid dynamics and finite element analyses were used to obtain the temperature distribution and to evaluate thermal stresses in nozzle materials. The materials investigated include tungsten carbide-cobalt (WC-6wt.% Co), hot pressed dense silicon carbide (SiC) and SiALON (Si3N4-Al2O3-AlN). The analysis and experiments showed that WC-CO nozzles prod...

Стратегія керування мобільною платформою з всенаправленим приводом

Purpose: Mobile robots are used in many areas of industry and commerce. This paper describes rese... more Purpose: Mobile robots are used in many areas of industry and commerce. This paper describes research on and development of a mobile platform, which is based on the concept of a ball-on-ball balancer, with two electrical drives at an angle of 90° providing a velocity vector in any direction in the horizontal plane. The purpose is to implement an originally novel principle for an omnidirectional mobile platform of very high agility, which is able at any given situation to move immediately in any direction without additional steering movements or steering mechanism. Methodology: In advance of the design and implementation of the control strategy for the mobile device, the method of theoretical modelling of the vehicle’s properties and behaviour was applied. The developed theoretical and numerical dynamic models take into account all the control parameters which allow for the determination of the critical value of angular acceleration of the driving wheel. This is needed to prevent any...

Development of a low-cost automatic guided vehicle (AGV)

Advances in Robotics & Automation, 2018

Development of a reconfigurable pallet system for a robotic cell

MATEC Web of Conferences, 2018

Advanced manufacturing systems allow rapid changes of production processes by means of reconfigur... more Advanced manufacturing systems allow rapid changes of production processes by means of reconfigurability providing mass customisation of products with high productivity, quality and low costs. Reconfigurable Manufacturing Systems (RMS) employ conventional as well as special purpose CNC machines, robots and material handling systems. In customised automated assembly, a number of different workpieces need to be processed simultaneously at various workstations according to their process plans. Therefore, a material handling system is an important part of RMS, whose main task is to provide reliable, accurate and efficient transfer of materials according to the process scheduling, without bottlenecks and stoppages. In this research, a reconfigurable pallet system was developed to facilitate automated robotic assembly for a highly customised production environment. The aim is to design a material handling system for conveying, sorting and processing of parts, which are supplied by robots ...

Enhancing the Accuracy of a CNC Machine using Artificial Neural Networks

Traditionally, geometric errors of CNC machine axes are rectified by means of calibration with su... more Traditionally, geometric errors of CNC machine axes are rectified by means of calibration with subsequent calculations of compensation values applied directly in a machine controller or with the aid of parameterised kinematic error models. The main drawback of these methods is that they require a calibration process, which can be not economically viable for some machine applications. In this research, the proposed approach is based on software compensation with the aid of Artificial Intelligence. The developed methodology allows for compensation of the displacement errors of the linear axes of a special purpose CNC machine using artificial neural networks. Two artificial neural networks, namely the Global Neural Network and the Global Vector Neural Network were applied. The artificial neural networks were derived from the data obtained in the drilling of a large number of holes, in a random sequence, in test plates located in the X-Y plane. The coordinates of the drilled holes were...

Measuring arm calibration

Conventional robot calibration techniques often make use of complex measurement equipment that ca... more Conventional robot calibration techniques often make use of complex measurement equipment that can only be operated by skilled personnel in laboratory environments. This paper presents the calibration of a 6DOF measuring arm with a method that requires no external measurement equipment. The arm is calibrated through the use of a kinematic constraint which allows the collection of training data. This data is then utilized by a genetic algorithm to determine improved Denavit-Hartenberg parameters.

Modelling of a Thermal Spraying Controller Using Matlab/Simulink

There are a number of thermal spraying systems, which are based on air flame processes. Stable co... more There are a number of thermal spraying systems, which are based on air flame processes. Stable control of such systems is difficult to achieve due to the complexity of the combustion process in a small burner and varying process parameters. Therefore, modelling of a system control can provide useful information in optimising the performance of thermal spraying systems. In this research, a simulation model of a thermal spray controller was developed using MATLAB/Simulink software. The model was evaluated by comparing the simulated and actual process parameters. The obtained results indicate that the developed model of system controller provides the main required control parameter, the fuel-air ratio, which corresponds with the optimal value used in the actual control of the thermal spraying system. Keywords—MATLAB/Simulink, modeling, control

Modelling of Boiler Drum Level Control using Flownex Software Environment

WSEAS TRANSACTIONS on SYSTEMS archive, 2019

Power plants are critical in producing the electricity required by modern society. In the majorit... more Power plants are critical in producing the electricity required by modern society. In the majority of countries in the world, including South Africa, the primary sources of electricity are fossil fuel power generation plants. A rapidly increase share of renewable generation places huge demands on conventional coalfired power plants. The inherent variability of renewable energy sources implies that coal-fired plants designed for continuous base load production must now be used for variable load. This can have negative effect on the overall efficiency and life expectancy of these plants. The challenge is, therefore, to balance the network demands with the power station operation, its thermal efficiency, availability and extended plant life expectancy. Hence, the main focus of the current research is on the efficiency of the boiler operation and control through modelling of the boiler subsystems, the processes and simulating various operating conditions, which include fluctuation loads...

Thermal stress evaluation of thermo-blast jet nozzle materials

Development of an affordable Automated Guided Cart for material handling tasks

The use of autonomous vehicles for material handling tasks in industry continues to grow because ... more The use of autonomous vehicles for material handling tasks in industry continues to grow because of higher productivity, improved ergonomics and safety aspects. Despite these advantages, the major drawback of implementing autonomous vehicles is their high cost, which makes it difficult to justify economically the automation of processes. Hence, there is a need to develop an affordable design of autonomous vehicle or Automated Guided Vehicle (AGV). AGVs designs and capabilities vary depending on the complexity of the task, the environment and the level of autonomy. As the AGV market is highly competitive, the designer and the manufacturer need to provide a low-cost solution without compromising the AGV functionality. An Autonomous Guided Cart (AGC) is one of variations of AGVs that provides automation of transporting tasks with a minimum level of control and complexity, and at an affordable cost. In this research, a low-cost AGC was developed specifically for a local automotive manuf...

Application of a Camera for Measuring Robot Position Accuracy

Conventional calibration of industrial robots is carried out with a use of special measurement eq... more Conventional calibration of industrial robots is carried out with a use of special measurement equipment, which is expensive and it also requires skilled personnel to operate. This paper presents a methodology, which utilises a camera to perform measurements of position accuracy of a robot. The experiments were conducted with a KUKA robot and a coupled measuring arm, as well as an in-door GPS (iGPS) in order to compare the results. The accuracy obtained with the camera is in agreement with the robot accuracy, and is better than the error measurement results of the measuring arm and the iGPS. Hence, it is envisaged that this methodology, together with numerical optimisation, can be used for robot calibration.

A Success of University–Industry Partnership

New Trends and Issues Proceedings on Humanities and Social Sciences, 2017

In the fast-changing world, the success of engineering education depends not only on sound engine... more In the fast-changing world, the success of engineering education depends not only on sound engineering knowledge, but also on the ability to apply it in practice from the moment young graduates enter the real industry. In order to be successful in industry, learners need interaction within the real industrial environment from the beginning of their studies. The importance of close links between engineering educational programmes and industry is shown in the example of industry–university collaboration between the Nelson Mandela Metropolitan University (NMMU) and General Motors South Africa (GMSA). The local automotive industry and GMSA, in particular, have been supporting the engineering programmes at NMMU for decades. However, with the establishment of a bachelor degree programme in mechatronics in 2005, GMSA decided to play an even more prominent role, as this was the first such degree programme in the Eastern Cape. This initiative has resulted in the establishment of the Chair of...

Modelling of boiler fireside control in flownex software environment

2015 Pattern Recognition Association of South Africa and Robotics and Mechatronics International Conference (PRASA-RobMech), 2015

With the influx of renewable generation technology and the constraints placed on the grid due to ... more With the influx of renewable generation technology and the constraints placed on the grid due to unplanned maintenance on aging power stations, coal fired stations designed for continuous base load production have to fulfil the role of frequency support. With the high inertia of the coal fired power stations, the dynamic operating philosophy of frequency support will impact negatively on the overall efficiency and life expectancy of these plants. The solution proposed is to develop a computational model of the boiler controllers capable of optimising boiler fireside control loops and control philosophies. The model will enable engineers to test and optimize various control parameters. The model will also be a safe environment for testing transient scenarios, such as the loss of a draught group or a multiple mill trip.

Development of a Controller for a Reconfigurable Manufacturing Cell

Reconfigurable Manufacturing Systems (RMSs) are widely used in modern production. The important f... more Reconfigurable Manufacturing Systems (RMSs) are widely used in modern production. The important features of RMSs, such as modularity, integrability and diagnosability, require open-architecture controllers. However, sub-systems from different vendors often use different communication protocols and interfaces. Hence, a RMS controller must be capable to overcome this drawback and allow easy control and integration of various types of controllers, devices and machines. This paper presents the development of a personal computer based cell controller, which is used for the control of a reconfigurable manufacturing cell. The SCADA control platform, developed with Movicon™ software, uses standard and special communication protocols

A new method for thermal spraying of Zn–Al coatings

Thin Solid Films, 2009

Abstract This paper presents the development of the thermal spraying system built on the principl... more Abstract This paper presents the development of the thermal spraying system built on the principles of the high velocity air flame (HVAF) process. HVAF sprayed coatings showed considerably higher bond strength than coatings obtained by the conventional methods, indicating the advantage of this method in areas where the adhesion strength is critically important. The highly dense structure of the coating obtained with HVAF eliminates a need for a top paint coat, which is typically applied on metal sprayed coatings to extend service life. The thermal sprayed coatings were characterized by the standard techniques, such as light microscopy, scanning electron microscopy with energy-dispersive spectroscopy, X-ray diffraction, salt spray and bond strength tests. The results show that thermal sprayed coatings have a dense structure, low presence of oxides and high resistance to corrosion. High spray rate and good coating quality make the HVAF thermal spray method a viable alternative to the conventional thermal spraying technologies, such as Wire Flame and Twin-Wire Arc.

Progress in Thermo-Abrasive Blasting Systems

The South African Journal of Industrial Engineering, 2012

A Comparative Study of Automation Strategies at Volkswagen in Germany and South Africa

The South African Journal of Industrial Engineering, 2012

The final car assembly lines at Volkswagen's production sites in Germany and South Africa are ana... more The final car assembly lines at Volkswagen's production sites in Germany and South Africa are analysed to determine the best automation level based on cost, productivity, quality, and flexibility for a plant location. The methodology used is proposed by the Fraunhofer Institute. The final assembly processes are analysed and classified according to the automation level. The operations are evaluated at every level of automation based on information from existing factories. If the best levels of automation for all the parameters correspond, the optimal level of automation for a plant is reached. Otherwise, improvements and/or additional considerations are required to optimise the automation level. The result of the analysis indicates that the highest automation level is not necessarily the best in terms of cost and quality, and some de-automation is required. The analysis also shows that a low automation level can result in poor product quality and low productivity. The best automation strategy should be based on the analysis of all the aspects of the process in the local context.

Validation of iGPS as an external measurement system for cooperative robot positioning

The International Journal of Advanced Manufacturing Technology, 2012

External metrology systems are increasingly being used in modern manufacturing to improve the acc... more External metrology systems are increasingly being used in modern manufacturing to improve the accuracy of industrial robots. In this paper, the problem of achieving absolute accuracy in the positioning and movement of cooperating robots is addressed using the indoor GPS (iGPS) technology as an external position measurement system for real-time feedback and control. This metrology system is presented as an introduction to the iGPS-based 3D Pose Detector and a new concept using generalised measurement systems inspired by iGPS. Attached to the robot end-effectors, the receivers allow coordinate frame measurements to provide spatial information on the robot poses in six degrees of freedom. Experimental results show a strong correspondence between iGPS measurements of cooperating robot end-effector positioning and the control measurements obtained from a double ballbar. Ballbar measurements are further used to determine the relative accuracy between state-of-the-art cooperating manipulators. The iGPS system is validated as an external measurement system using a ballbar device, and its use in the external control of basic robotic tasks is demonstrated. The predicted accuracy achievable for the robots when being controlled or compensated is

Development of an Automated Guided Vehicle Controller Using a Systems Engineering Approach

SOUTH AFRICAN JOURNAL OF INDUSTRIAL ENGINEERING

Automated guided vehicles (AGVs) are widely used for transporting materials in industry and comme... more Automated guided vehicles (AGVs) are widely used for transporting materials in industry and commerce. In this research, an intelligent AGV-based material-handling system was developed using a modelbased systems engineering (MBSE) approach. The core of the AGV, the controller, was designed in the system modelling language environment using Visual Paradigm software, and then implemented in the hardware. As the result, the AGV's complex tasks of material handling, navigation, and communication were successfully accomplished and tested in the real industrial environment. The developed AGV is capable of towing trolleys with a weight of up to 200kg at walking speed. The AGV can be incorporated into an intelligent material-handling system with multiple autonomous vehicles and work stations, thus providing flexibility and reconfigurability for the whole manufacturing system. Ergonomic and safety aspects were also considered in the design of the AGV. A comprehensive safety system that is compliant with industrial standards was implemented.

Navigation and locomotion of a low-cost Automated Guided Cart

2015 Pattern Recognition Association of South Africa and Robotics and Mechatronics International Conference (PRASA-RobMech), 2015