The ERC testbed was built in 1998 with the purpose to test and demonstrate the science base for RMS. In particular, the testbed has the following goals:

• Proof-of-concept demonstration
• Integration of research results from different projects and thrust areas
• Hands-on education of students
• Serve as a "learning factory" for industry.

Most recent testbed efforts have focused on the Reconfigurable Factory Testbed (RFT), which supports integration of several projects from multiple thrust areas, as well as on our various prototype machines (two RMTs, two RIMs, and cylinder bore inspection systems). During the last year, we have also advanced several other projects from the laboratory demonstrations to actual industry site validation (e.g., the RIM at Cummins, the SoV at Ford, and cylinder bore inspection system at DaimlerChrysler engine plant). We added this year to the testbed area three exploratory projects on manufacturing of medical devices (which is an important area for the US), array of inexpensive vision sensors with sophisticated compensation algorithms, and reconfigurable grippers and fixtures. Altogether the testbed area includes four projects. Below we elaborate on the prototype machines and the RFT.

Machine Level Hardware Testbed:

The major emphasis of the machine level hardware testbed has been on the performance evaluation and analysis of an innovative, arch-type reconfigurable machine tool that was built in 2002 based on an ERC patent. This unique RMT was designed through the use of the scientific tools developed by the Center researchers, and tailored to machine any family of automotive cylinder heads. The current investigations focus on the evaluation of the RMT's dynamic performance with respect to the reconfiguration changes and on the fast calibration after machine reconfigurations. Two prototype reconfigurable inspection machines (RIM) have also been designed and built. The first RIM was designed for in-process, rapid and high-accuracy inspection of parts from a given part-family. It does not have the general flexibility of a CMM, but offers the flexibility needed for a given part family, granting an in-line, non-contact measurement of part dimensions, while providing cost-effective high-speed. The RIM has been integrated into the system level hardware testbed and with the stream of variations (SoV) methodology. The second RIM is a portable reconfigurable inspection machine that was designed to demonstrate the technology at industrial sites and facilitate the technology transfer. It has been successfully presented at IMTS 2004 in Chicago and also at our industrial member's site (e.g., Cummins Engine, DaimlerChrysler).

An example of integration between projects within a testbed is the integration between the Reconfigurable Inspection Machine (RIM) and the Stream of Variations (SoV) methodology. This integration paves the path towards improved closed loop quality control methodology. The RIM produces improved inspections with improved speed while the SoV closes the control feedback loop by analyzing these results and identifying the root causes of errors in the machining line. The ability to provide rapid feedback will dramatically reduce the number of defective parts produced. Thus the quality and the efficiency of the production line will be increased with this integration. The integration between the two systems was implemented at a basic level. However, due to the reconfigurable nature of the RIM, the integration between the two systems can be extended further.

Reconfigurable Factory Testbed (RFT):

(For additional information, see our Reconfigurable Factory Testbed page.)

This major effort undertaken by TA-2 researchers over the past three years has been the design and construction of a new testbed, called the "reconfigurable factory testbed" or RFT. This testbed is being used for demonstration and testing of reconfigurable control strategies that have been developed in the center, as well as for educational projects both at UM and at partnering universities (e.g., Morgan State University, or MSU). In fact, this RFT was extensively used in last year's NSF site visit at MSU. The UM part of the testbed has a significant hardware component, consisting of four table-top machine tools, two full-scale industrial robots, and a conveyer. The MSU part of the testbed includes automated storage & retrieval system (AS/RS), a conveyer and lathe (or mill-turn machine) and a robot. The key difference between the RFT and the system-level hardware testbed is that the controls are an important part of the testbed as well as the material handling system being an integral part of the system. An AGV is used to bring parts to and from the testbed. Several different control networks are being used (such as DeviceNet, Profibus, Ethernet, SafetyBus). Control software developed at the ERC (Modular Finite State Machines for Logic Control) coordinates with Rockwell and Siemens PLCs. A virtual factory simulates the hardware that currently exists, for controls testing purposes, or it can simulate hardware that doesn't exist yet, for controls development purposes. All of the controllers are integrated using the industrial OPC communication standard . Future plans in testbed development include both near term and long-term activities. The near term plans focus mainly on the further improvement of the ERC testbeds with a goal to achieve better integration of research projects not only in the TA level, but also across different TAs. The long-term activities of the testbed development will be supporting the new initiatives of the ERC over the next few years. Based on the above testbed strategy, the following activities are proposed for next year.