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Thesis Submitted for the Degree of Doctor of Philosophy University of Bath PHD Resource-Independent Computer Aided Inspection Mahmoud, Hesham Award date: 2016 Awarding institution: University of Bath Link to publication Alternative formats If you require this document in an alternative format, please contact: [email protected] General rights Copyright and moral rights for the publications made accessible in the public portal are retained by the authors and/or other copyright owners and it is a condition of accessing publications that users recognise and abide by the legal requirements associated with these rights. • Users may download and print one copy of any publication from the public portal for the purpose of private study or research. • You may not further distribute the material or use it for any profit-making activity or commercial gain • You may freely distribute the URL identifying the publication in the public portal ? Take down policy If you believe that this document breaches copyright please contact us providing details, and we will remove access to the work immediately and investigate your claim. Download date: 10. Oct. 2021 Resource-Independent Computer Aided Inspection Hesham Abdelfattah Mahmoud A thesis submitted for the degree of Doctor of Philosophy University of Bath Department of Mechanical Engineering August 2016 COPYRIGHT Attention is drawn to the fact that copyright of this thesis rests with the author. A copy of this thesis has been supplied on condition that anyone who consults it is understood to recognise that its copyright rests with the author and that they must not copy it or use material from it except as permitted by law or with the consent of the author. This thesis may be made available for consultation within the University Library and may be photocopied or lent to other libraries for the purposes of consultation. Signed.................................... ABSTRACT Quality is of paramount importance when establishing and maintaining market share in any manufacturing sector. Measurement is a critical tool in ensuring product conformance and is a major enabler in the control of manufacturing processes to improve and maintain quality. Furthermore, measurement is evolving into a value-adding process in its own right and the gained measurement knowledge has become crucial for both design and manufacturing stages. Despite this ever increasing importance, measurement planning and execution is still carried out with great reliance on manual operations and ambiguous practice guidelines utilising tools and software that are very specific to the individual pieces of equipment used in the measurement process. In addition, in industry, measurement plans are defined in isolation instead of in an integrated and interoperable manner with other manufacturing activities. This research aims to formulate an interoperable integration framework for defining measurement processes through the introduction and realisation of resource- independent measurement specifications (REIMS). REIMS is a data model that represents both measurement features and operations to enable their exchange between computer aided for x (CAx) applications. REIMS enables measurement process definitions to be exchanged between various measurement geographical locations and resources within a distributed manufacturing system. It, therefore, reduces the recently identified variability due to the measurement planning phase that varies depending on the experience and skills of the measurement operators. REIMS also removes an integration barrier at the measurement planning-execution interface and assists in obtaining consistent measurement knowledge. Comparable measurement knowledge is crucial for taking proper decisions for improving both design and machining phases. This thesis uses system engineering methods for analysing the measurement process and its data flow and requirements. As a result of this analysis, the REIMS data model has been developed based on the STEP modelling and implementation mechanisms to formulate a computer interpretable format of the measurement process data. STEP-based methods have been selected as the framework as they have been previously validated for interoperable data exchange between design and machining applications. The theoretical basis of REIMS is the concepts and definitions presented in the ISO standardised documents for “geometric product specifications (ISO GPS)” as these documents, for the first time in the domain, consider design specifications and measurement activities in relation to each other. ii The REIMS data model has been realised and a prototype implementation has been designed utilising the CTC-01 test case encoded as an ISO10303-242 compliant model. This test case has previously been used by the national institute of standards and technology (NIST) for validating the exchange of design data including product manufacturing information (PMI) between different CAD systems and as such provides an authoritative example. The implementation framework uses C++ and ST-Developer to obtain the design information from the AP242 file data and demonstrates the ability of the REIMS data model to map design specifications into measurement features and to define the necessary measurement operations to complete the process definition. An ISO10303-21 compliant file has then been constructed from the REIMS data to establish the proposed data exchange mechanism. Based on the findings of this thesis, the REIMS provides a coherent, comprehensive and flexible framework for representing the measurement process. Through adoption of REIMS as the standardised framework for measurement planning, companies could ensure the consistency of the measurement knowledge that is gained and maintained in the enterprise regardless of the location or equipment. This would facilitate the spread the measurement process benefits throughout the digital factory with potential for cost saving due to resource fluidity, a significant decrease in plan translation errors and reducing the equipment specific training requirements. iii Lovingly dedicated to my dear parents, my beloved wife May and my children Noor and Omar OmarMohamed iv Acknowledgements First and foremost, I am grateful to God for the good health, well-being and determination that were necessary to complete this research. I would like also to express my special appreciation and gratitude to my supervisors Dr. Aydin Nassehi and Dr. Vimal Dhokia for their continuous support, comments and advice on all aspects related to my research and thesis; for their motivation, patience and immense knowledge in addition to the expertise I have absorbed from them. I could not have imagined having better supervision for my PhD study as I have greatly benefited from the excellent and supportive supervision ethics that are rooted from the AMPS research team leader Prof. Stephen Newman. My sincere thanks also go to my colleagues Dr. Alborz Shokrani and the members of the AMPS research group for the valuable working environment and continuous care and support they provided me during the research period. I would like also to thank Dr. Nigel Johnston and all the postgraduate members for their efforts in monitoring my progress and facilitating the administrative steps related to the study. I place on record, my thanks to all the Mechanical Engineering Department staff and members at the university of BATH for the welcoming and encouraging research environment that affected me during the hard phases of this postgraduate research. Words cannot express how grateful I am to my parents, the reason for my existence in this world, for their continuous prayers for me what sustained me thus far; and my beloved wife May Mohamed for her strong sacrifices and sleepless nights for supporting me to face various challenges in my life and career. I am owed to my children Noor and Omar for providing me with motivation to finishing this research to make them proud, and for the positive boost, they provide me via their lovely smiles and souls. I would like to thank my sisters for providing me with the moral support and encouragement all over my life and all my family members and friend who give me advice and support to pass through difficulties. Many thanks for the administrative support I have been provided with from the Egyptian government through funding my PhD research and all the administrative and academic members who worked on monitoring my progress and helped in solving the problems and challenges faced during the research; especially mentioned Dr. Amro Yossef.. v LIST of ABBREVIATIONS 1D One-Dimensional 2D Two-dimensional 3D Three-Dimensional AAM Application Activity Model AIAG Automotive Industries Action Group AICs Application Interpreted Constructs AIM Application Interpreted Model ALPS A Language for Process Specification AM Application Modules ANSI American National Standards Institute API Application Programming Interface APs Application Protocols ARM Application Reference Model ASME American Society of Mechanical Engineering B-rep Boundary Representation CAD Computer Aided Design CAI Computer Aided Inspection CAIP Computer Aided Inspection Planning CAM Computer Aided Manufacturing CAPP Computer Aided Process Planning CAT Computer Aided Tolerancing CAx Computer Aided for x application CAx-IF CAx Implementation Forum CIM Computer integrated Manufacturing CLM Closed Loop Manufacturing CMM Coordinate Measuring Machine CNC Computer Numerical Control CSG Constructive Solid Geometry CT Category Theory CZ Combined Zone DET Digital Enterprise Technology DIS
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