Chapter

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Abstract

From the theoretical point of view, the chapter focuses on the unification of views on the living (constantly changing) structure of the construction of flexible production systems, including its cooperating devices. It contains currently defined and designated technical terms in the field of flexible production systems. From the theoretical point of view, the existing structures of the “multiprofessional manufacturing robotic center” are enhanced with new elements, which also contributes to innovation and expansion of their applications. These structural structures served as the basis for building sophisticated modular structures. Modularity is an integrating element directed at highly customizable manufacturing engineering structures. It fully complies with the requirements of manufacturing practice and demanding market, in the framework of fully implemented Industry 4.0 (I4.0) under way.

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1. Introduction

Modular manufacturing systems, as an integrated part of flexible manufacturing systems, deserve an unmistakable merit in today’s rapidly changing manufacturing environment, characterized by developed competition in the global context and progressive changes in process technologies and in their structure according to market requirements. Such systems necessitate a rapid and factual integration of new technologies and new functions into both system and process relationships.

The Industry 4.0 (I4.0) trends and conditions and requirements require cyber and flexible production-oriented approach, enabling to build the following:

  • A production capacity of production systems that is operatively adaptive to market requirements, i.e., obtaining new, rapidly viable products

  • Fast integration of modern process technologies and new functions into existing production systems and their easy adaptation to dynamically changing batches of individual products

  • Integrated production units with new service capabilities based on robust Industry Internet of Things (IIoT) data streams from individual work units and their accessibility for being processed from anywhere subject to Internet connection

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2.1 New approach to production systems classification

In the area of production systems, a number of terms are used with broader interpretation. This situation is related to approaches to and perspectives on this issue. A proposal for their general unification and effective classification is given in Figure 2 .

Figure 2.

Open proposal for production systems classification.

Various definitions of production systems from different points of view are cited in various literature sources [1]. This has led to the need to harmonize these formulations so that they provide the most precise definitions, taking into account current knowledge in this area:

Flexible production system—afunctional grouping of production facilities linked by material flow and information network, enabling the use of flexible change in production facilities due to the introduction of new products in relatively short time intervals, to produce small quantities efficiently.

Structural production system—flexible set of compatible elements (technological and positioning units, supporting frame, cooling system, etc.) and their mutual links, which can be expanded with new elements to change the system parameters.

Modular system—flexible set of unified modules (module—separately functional unit) in functionally logical (in terms of structure, system, concept, kinematics, etc.) arrangement into higher functional unit (meeting required parameters and working functions).

Reconfigurable system—a modular system with the possibility to change the arrangement of its own modules (in terms of structure, system, concept, kinematics, etc.) in order to create an innovated system with innovated properties.

Self-reconfigurable system—a reconfigurable system capable of independently reconfiguring its own modules (in terms of structure, system, concept, kinematics, etc.) to create an innovated system with innovated features.

Metamorphic system—a closed self-reconfigurable system to create an innovated system with innovated features (def. Inspired by [4]).

Fractal system—an open, self-reconfigurable system consisting of proactively behaving elements—fractals (their structure is recurrent) which pursue a common goal (def. Inspired by [5]).

2.2 Modular production centers

In the category of manufacturing technology, machining centers (MC) are defined as manufacturing machines designated for complex components machining with defined characteristics. According to the number and type of technological operations performed, machining centers are divided into:

  • Multipurpose (multi-operation)—machines with a predominant technological operation (e.g., turning), i.e., they mostly enable one type of technology

  • Multiprofessional (multiprofessional productions center (MPC))—machines on which various technological operations can be performed (e.g., turning, milling, drilling, etc.)

 

Production centers are conceptually built on the principles of modular systems or as modular single-purpose machines. In terms of design and structure, they are assembled from technological, handling, and auxiliary units (mechanical, electromechanical, hydraulic, pneumatic) integrated through a supporting element (frame) into one functional and structural unit. The highest integration of production centers is based on the automation of technological and handling operations. These are multiprofessional machine tools designed for complex machining of parts on one machine and, if possible, requiring one clamping. To machine a workpiece requiring one clamping, its rotation must be ensured (e.g., in the X-Y plane) and so must be its tilting. The machining centers are equipped with a tool magazine automatically replaced by a mechanical hand. Some tools feature their own drive, which makes drilling off the workpiece axis or its milling possible, especially on lathes. Machining centers represent the basic AVS production machines. They are mainly used in piece and small batch production. Machining centers are characterized by a high concentration of operations. The machining is often carried out with the component clamped only once. They are mostly equipped with tool magazines exchanged automatically as needed. The most common main feature of machining centers is the largest machined part dimension.

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2.1 New approach to production systems classification

In the area of production systems, a number of terms are used with broader interpretation. This situation is related to approaches to and perspectives on this issue. A proposal for their general unification and effective classification is given in Figure 2 .

Figure 2.

Open proposal for production systems classification.

Various definitions of production systems from different points of view are cited in various literature sources [1]. This has led to the need to harmonize these formulations so that they provide the most precise definitions, taking into account current knowledge in this area:

Flexible production system—afunctional grouping of production facilities linked by material flow and information network, enabling the use of flexible change in production facilities due to the introduction of new products in relatively short time intervals, to produce small quantities efficiently.

Structural production system—flexible set of compatible elements (technological and positioning units, supporting frame, cooling system, etc.) and their mutual links, which can be expanded with new elements to change the system parameters.

Modular system—flexible set of unified modules (module—separately functional unit) in functionally logical (in terms of structure, system, concept, kinematics, etc.) arrangement into higher functional unit (meeting required parameters and working functions).

Reconfigurable system—a modular system with the possibility to change the arrangement of its own modules (in terms of structure, system, concept, kinematics, etc.) in order to create an innovated system with innovated properties.

Self-reconfigurable system—a reconfigurable system capable of independently reconfiguring its own modules (in terms of structure, system, concept, kinematics, etc.) to create an innovated system with innovated features.

Metamorphic system—a closed self-reconfigurable system to create an innovated system with innovated features (def. Inspired by [4]).

Fractal system—an open, self-reconfigurable system consisting of proactively behaving elements—fractals (their structure is recurrent) which pursue a common goal (def. Inspired by [5]).

2.2 Modular production centers

In the category of manufacturing technology, machining centers (MC) are defined as manufacturing machines designated for complex components machining with defined characteristics. According to the number and type of technological operations performed, machining centers are divided into:

  • Multipurpose (multi-operation)—machines with a predominant technological operation (e.g., turning), i.e., they mostly enable one type of technology

  • Multiprofessional (multiprofessional productions center (MPC))—machines on which various technological operations can be performed (e.g., turning, milling, drilling, etc.)

 

Production centers are conceptually built on the principles of modular systems or as modular single-purpose machines. In terms of design and structure, they are assembled from technological, handling, and auxiliary units (mechanical, electromechanical, hydraulic, pneumatic) integrated through a supporting element (frame) into one functional and structural unit. The highest integration of production centers is based on the automation of technological and handling operations. These are multiprofessional machine tools designed for complex machining of parts on one machine and, if possible, requiring one clamping. To machine a workpiece requiring one clamping, its rotation must be ensured (e.g., in the X-Y plane) and so must be its tilting. The machining centers are equipped with a tool magazine automatically replaced by a mechanical hand. Some tools feature their own drive, which makes drilling off the workpiece axis or its milling possible, especially on lathes. Machining centers represent the basic AVS production machines. They are mainly used in piece and small batch production. Machining centers are characterized by a high concentration of operations. The machining is often carried out with the component clamped only once. They are mostly equipped with tool magazines exchanged automatically as needed. The most common main feature of machining centers is the largest machined part dimension.

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