Knowledge Base Engineering

Abstract. In open source software (OSS) project development typically tools and models originating from heterogeneous background are used. Project managers want to analyze the state of project across these artifacts but often face the challenge of linking semi-structured information ...

The intensified use of CFD techniques for dimensioning and design evaluation of aerodynamic geometries in a jet engine has increased the need for automation of engineering activities. One of the bottlenecks today is the lead time to update the CAD master model based on CFD results. The master model used as a base for the associated context model within different CAE disciplines. The context model is a simplified geometry used for CAE analysis. Another issue is the quality of the geometry representation which must be possible to use in down stream manufacturing processes. This paper describes a Knowledge Based Engineering (KBE) approach to automate the CFD blade design within a CAD system. The approach has been formalized and an application has been developed as a system support. The application utilizes geometric result from a CFD blade design code and provides a 3D CAD geometry. Output is used both in internal aerodynamic design loops for optimization of the blade profile and to update the CAD Master Model for continuing with the multidisciplinary iterative design process. The application was developed and tested in an iterative process where domain expertise within CFD and CAD/KBE co-designed the application. The method was implemented using a KBE module from UGS, Knowledge Fusion. The CFD code was an in-house blade design system. The application, together with a context model and a predefined parametric mesh, has reduced the lead time for trade studies of design alternatives from hours to minutes with an improvement in quality and less sensitivity regarding staff turnover in the engineering expertise. The main benefit is that design iterations previously 'local' to CFD now include a CAD master model update. The application is designed as a combination of method modules; the advantage is an increased re-usability. An additional benefit with the modular architecture of the blade design application is the possibility to re-use the application in other KBE applications. Similar benefits appear in cost reduction work and production support where engineering work similar to conceptual design work is performed. The approach enables continues improvement, a step towards an integrated methodological toolbox.

The development process of the knowledge-based engineering (KBE) system for the structural size optimization of external fixation device is presented in this paper. The system is based on algorithms for generative modeling, finite element model (FEM) analysis, and size optimization. All these algorithms are integrated into the CAD/CAM/CAE system CATIA. The initial CAD/FEM model of external fixation device is verified using experimental verification on the real design. Experimental testing is done for axial pressure. Axial stress and displacements are measured using tensometric analysis equipment. The proximal bone segment displacements were monitored by a displacement transducer, while the loading was controlled by a force transducer. Iterative hybrid optimization algorithm is developed by integration of global algorithm, based on the simulated annealing (SA) method and a local algorithm based on the conjugate gradient (CG) method. The cost function of size optimization is the minim...

The actual product ownership often remains with the manufacturer as functional (total care) products emerge in aerospace business agreements. The business risk is then transferred to the manufacturer why downstream knowledge needs to be available in the concept phase to consider all product life cycle aspects. The aim of this work is to study how a multidisciplinary design tool can be used to embed downstream processes for conceptual design and evaluation allowing simulation of life cycle properties. A knowledge enabled engineering approach was used to capture the engineering activities for design and evaluation of jet engine component flanges. For every design change, cost of manufacturing operations, maintenance and performance aspects can be directly assessed. The design tool assures that the engineering activities are performed accordingly to company design specification which creates a better control over the process quality. It also creates a better understanding enabling the ...

Engineering effort is often concentrated on established design patterns. Within these patterns, knowledge develops through research, innovation, experiment and test. The paper first describes patterns of development in incremental design, including changes in customer demands and design constraints, in understanding of the relationship between the design performance and design attributes, and in understanding of the uncertainty in such relationships. Guidelines are then developed concerning the choice of the changes that develop the design, with the aim of allowing organisations to judge where to devote research and development effort and when to adopt more or less radical product design strategies. The level of design support and automation that may be possible though computer-aided design tools is then discussed, based on a spectrum of stages of development of knowledge in design.

The use of external fixation devices is considered a valuable approach for the treatment of bone fractures, providing proper alignment to fractured fragments and maintaining fracture stability during the healing process. The need for external fixation devices has increased due to an aging population and increased trauma incidents. The design and fabrication of external fixations are major challenges since the shape and size of the defect vary, as well as the geometry of the human limb. This requires fully personalized external fixators to improve its fit and functionality. This paper presents a methodology to design personalized lightweight external fixator devices for additive manufacturing. This methodology comprises data acquisition, Computer tomography (CT) imaging analysis and processing, Computer Aided Design (CAD) modelling and two methods (imposed predefined patterns and topology optimization) to reduce the weight of the device. Finite element analysis with full factorial de...

Development process of Knowledge Based Engineering (KBE) system for structural size optimization of external fixation device is presented in this paper. System is based on algorithms for generative modeling, finite element model (FEM) analysis and size optimization. All these algorithms are integrated in CAD/CAM/CAE system CATIA. Initial CAD/FE model of external fixation device is verified using experimental verification on real design. Experimental testing is done for axial pressure. Axial stress and displacements are measured using tensometric analysis equipment. The proximal bone segment displacements were monitored by a displacement trans-ducer, while the loading was controlled by a force transducer. Iterative hybrid optimization algorithm is developed by integration of global algorithm, based on Simulated Annealing (SA) method and local algorithm based on Conjugate Gradient (CG) method. Cost function of size optimization is minimization of design volume. Constrains are given in a form of clinical interfragmentary displacement constrains, at the point of fracture and maximum allowed stresses for material of external fixation device. Optimization variables are chosen as design parameters of external fixation device. Optimized model of external fixation device has smaller mass, better stress distribution and smaller interfragmentary displacement in correlation to initial model.

Innovation and knowledge creation-these two concepts have a strong relationship but this relationship has not been examined systematically. This paper reviews the important theoretical work in both streams of research, highlighting the fundamental similarities and differences. Four major models of innovation are compared, and the distinction between radical and incremental innovation is examined. The nature of organizational knowledge and the process of knowledge creation are presented. We then compare the principal findings of the research on innovation and knowledge creation, and conclude with a new framework that differentiates types of innovation based on a knowledge creation perspective.

The actual product ownership often remains with the manufacturer as functional (total care) products emerge in aerospace business agreements. The business risk is then transferred to the manufacturer why downstream knowledge needs to be available in the concept phase to consider all product life cycle aspects. The aim of this work is to study how a multidisciplinary design tool can be used to embed downstream processes for conceptual design and evaluation allowing simulation of life cycle properties. A knowledge enabled engineering approach was used to capture the engineering activities for design and evaluation of jet engine component flanges. For every design change, cost of manufacturing operations, maintenance and performance aspects can be directly assessed. The design tool assures that the engineering activities are performed accordingly to company design specification which creates a better control over the process quality. It also creates a better understanding enabling the engineers to optimize the concept in real time from an overall product life cycle view. The new tool will be the base for optimize the total product system and will be used not only between companies but also between product development departments in large global companies.

In the production of automotive body components, fixtures are an important part of the ongoing work on geometrical assurance. The fixture is uniquely defined for each component, and the design and configuration of these are time-consuming and takes a lot of effort. The objective with this paper is to explore the use of a design automation approach and application to semi-automate the configuration process of the fixture product. The paper presents an approach to automate the configuration of the fixtures in a flexible way, by reverse engineering the configuration of the fixture product from a generic blueprint that represents the expected outcome of the process, using a knowledge-based engineering approach applied to a computer aided design (CAD) environment. A reverse-engineered design automation toolbox for a CAD-software is developed. The toolbox is developed to lead a user through the configuration process, in the way that the experts want it done, end-to-end, making use of some...

In production of automotive components, control-measuring is an important activity to assure that geometries meet expected tolerances. This is done via randomly taking parts out of production for control-measuring in a fixture. This fixture is both a tedious and repetitive product to design and configure. The aim of this paper is therefore to present an approach to adopt a design automation strategy towards supporting the configuration of fixtures and to discuss opportunities for moving towards a Product-Service System-paradigm in this domain. This paper reports on a development of a design automation demonstrator to configure fixtures for control-measuring. The demonstrator has been developed in a commercial CAD-environment and will be deployed through a web-based interface. The paper concludes with a discussion on PSS-opportunities and how to drive this with a Knowledge-Based Engineering-modelling approach.

The objective of this paper is to discuss how Knowledge Enabled Engineering, when combined with simulation methods is a development step for product development processes, engineering design methods and evaluation support systems. The paper opens the discussion on how these approaches, ie work methods, simulation support and Knowledge Enabled Engineering (KEE) methods affects best practice in engineering design (ED) by adding synthesis support to the already existing analysis support. In the presented ...

A manufacturing company's unique intellectual capital is to a large extent built on experience from its own product development and manufacturing processes. Thus, methods and tools to utilize and benefit from this experience in an efficient way have an impact on a company's ability to stay competitive and advance on the global market. Knowledge Based Engineering (KBE) is an engineering methodology to capture engineering knowledge systematically into the design system. Hence, KBE tools are considered to support experience re-use and improve engineering activities. This paper presents the results from a study where the objective was to investigate the support for experience re-use in KBE applications in an aerospace company. A proposed framework is presented to analyze the capturing and use of experience in a company's processes identifying gaps and propose improvements. The study revealed weaknesses in the process steps for experience feedback which can be used to improve KBE applications further.

This paper presents a systematic method for designing part families whose production costs are insensitive to changes in production plans due to market demand fluctuations. A unified feature-based representation of functional geometry and manufacturability has been developed to manipulate and evaluate part designs. Based on this information and production plans for multiple periods, an optimization-based method provides alternative part designs. The manufacturability of the part designs is quantitatively estimated by the facility cost of the manufacturing system best configured for a given part family and the average cycle time estimated by the discrete event simulation of production scenarios. Redesign suggestions are made on datum definitions of the original parts. Two case studies of a family of prismatic parts and that of turned parts are given to demonstrate the effectiveness of the proposed method.

Automating redesign is an approach for engineering designers to prevent design related manufacturability problems in early product development and thus reduce costly design iterations. A vast amount of work exists, with most research findings seemingly staying within the research community rather than finding its way into use in industrial settings where research issues have often evolved from the concerned applied research. The aim of this paper is to present an approach with industrial implementation potential regarding automating redesign of sheet-metal components in early product development to avoid manufacturing problems due to design flaws and non-optimal designs. Geometry, generated by a knowledge-based engineering (KBE) system, gives input to the case-based reasoning (CBR) governed manufacturing planning. If geometry is found non-manufacturable or enhancement of already manufacturable geometry is possible, the CBR system will suggest redesign actions to resolve the problem. CBR extends the capabilities of the rule-based KBEsystem by enabling plan-based evaluation. The approach has the potential for industrial implementation, since KBE is often closely coupled to an industrial CAD-system, hence enabling technology is at the industry. Also, combining KBE and CBR reduces the coding effort compared to coding the whole design support with CBR, as feature recognition is simplified by means of KBE. A case study of development of sheet-metal manufactured parts at a Swedish automotive industry partner presents the method in use. As it is shown that redesign can be automated for sheet-metal parts there is a potential for reducing costly design and manufacturing iterations.

The actual product ownership often remains with the manufacturer as functional (total care) products emerge in aerospace business agreements. The business risk is then transferred to the manufacturer why downstream knowledge needs to be available in the concept phase to consider all product life cycle aspects. The aim of this work is to study how a multidisciplinary design tool can be used to embed downstream processes for conceptual design and evaluation allowing simulation of life cycle properties. A knowledge enabled ...

Increasingly, manufacturers become service providers rather than product providers. In this work, a framework based on industrial studies is suggested for developing product service system. The framework is represented by six life cycle phases where three actor categories views are represented. The framework is described using examples from different industries/businesses. The intention is that the framework can be used for both B2C and B2B type of relations. One significant characteristic is that the “traditional” sales phase is ...

The objective of this paper is to discuss how Knowledge Enabled Engineering, when combined with simulation methods is a development step for product development processes, engineering design methods and evaluation support systems. The paper opens the discussion on how these approaches, ie work methods, simulation support and Knowledge Enabled Engineering (KEE) methods affects best practice in engineering design (ED) by adding synthesis support to the already existing analysis support. In the presented ...

The actual product ownership often remains with the manufacturer as functional (total care) products emerge in aerospace business agreements. The business risk is then transferred to the manufacturer why downstream knowledge needs to be available in the concept phase to consider all product life cycle aspects. The aim of this work is to study how a multidisciplinary design tool can be used to embed downstream processes for conceptual design and evaluation allowing simulation of life cycle properties. A knowledge enabled engineering approach was used to capture the engineering activities for design and evaluation of jet engine component flanges. For every design change, cost of manufacturing operations, maintenance and performance aspects can be directly assessed. The design tool assures that the engineering activities are performed accordingly to company design specification which creates a better control over the process quality. It also creates a better understanding enabling the engineers to optimize the concept in real time from an overall product life cycle view. The new tool will be the base for optimize the total product system and will be used not only between companies but also between product development departments in large global companies.

Automating redesign is an approach for engineering designers to prevent design related manufacturability problems in early product development and thus reduce costly design iterations. A vast amount of work exists, with most research findings seemingly staying within the research community rather than finding its way into use in industrial settings where research issues have often evolved from the concerned applied research. The aim of this paper is to present an approach with industrial implementation potential regarding automating redesign of sheet-metal components in early product development to avoid manufacturing problems due to design flaws and non-optimal designs. Geometry, generated by a knowledge-based engineering (KBE) system, gives input to the case-based reasoning (CBR) governed manufacturing planning. If geometry is found non-manufacturable or enhancement of already manufacturable geometry is possible, the CBR system will suggest redesign actions to resolve the problem. CBR extends the capabilities of the rule-based KBEsystem by enabling plan-based evaluation. The approach has the potential for industrial implementation, since KBE is often closely coupled to an industrial CAD-system, hence enabling technology is at the industry. Also, combining KBE and CBR reduces the coding effort compared to coding the whole design support with CBR, as feature recognition is simplified by means of KBE. A case study of development of sheet-metal manufactured parts at a Swedish automotive industry partner presents the method in use. As it is shown that redesign can be automated for sheet-metal parts there is a potential for reducing costly design and manufacturing iterations.

Automating redesign is an approach for engineering designers to prevent design related manufacturability problems in early product development and thus reduce costly design iterations. A vast amount of work exists, with most research findings seemingly staying within the research community rather than finding its way into use in industrial settings where research issues have often evolved from the concerned applied research. The aim of this paper is to present an approach with industrial implementation potential regarding automating redesign of sheet-metal components in early product development to avoid manufacturing problems due to design flaws and non-optimal designs. Geometry, generated by a knowledge-based engineering (KBE) system, gives input to the case-based reasoning (CBR) governed manufacturing planning. If geometry is found non-manufacturable or enhancement of already manufacturable geometry is possible, the CBR system will suggest redesign actions to resolve the problem. CBR extends the capabilities of the rule-based KBEsystem by enabling plan-based evaluation. The approach has the potential for industrial implementation, since KBE is often closely coupled to an industrial CAD-system, hence enabling technology is at the industry. Also, combining KBE and CBR reduces the coding effort compared to coding the whole design support with CBR, as feature recognition is simplified by means of KBE. A case study of development of sheet-metal manufactured parts at a Swedish automotive industry partner presents the method in use. As it is shown that redesign can be automated for sheet-metal parts there is a potential for reducing costly design and manufacturing iterations.

Product-Service Systems (PSS) introduces the possibility to change into a resultoriented perspective of product development. This means a focus on ‘performance of the product’, rather than on the standalone goods. Also, PSS is foreseen to bring about possibilities to address sustainability in early phases of product development. For instance remanufacture and upgrading of the goods become attainable in different ways than before. In aeronautic industry PSS is seen as an opportunity to deal with the issues of sustainability, for example lowering CO2 and NOX emissions of the jet engine. In turn, the companies have to learn how to manage more abstract information from customers, but also, address breakthrough innovation in collaboration with partner companies. This paper builds on empirical studies for the purpose to contend with the question how knowledge
based (KBE) tools used in companies today are apt to manage innovation aspects.

By being aware of and reusing knowledge in the form of expertise and engineering know-how throughout the whole organization large time-savings can be made. The knowledge allows for alternative studies where different configurations can be compared and balanced. A method called Knowledge Based
Engineering (KBE) can act as a valuable tool to help capturing this knowledge and guaranteeing quality of a product.

The work described in this thesis focuses on developing methods to support the generation of a weld simulation model used for a jet engine component. The geometry of the model is treated in a general manner that allows for substitution in the future. Subcomponents within the model can be individually treated or combined with other subcomponents to create a
complete system. An automated method for mesh generation is developed and implemented.

The methods not only result in shortening lead-times but also assures consistency and quality every time they are asked for. They can be reused and further expanded to support other types of configurations in the future.

The actual product ownership often remains with the manufacturer as functional (total care) products emerge in aerospace business agreements. The business risk is then transferred to the manufacturer why downstream knowledge needs to be available in the concept phase to consider all product life cycle aspects. The aim of this work is to study how a multidisciplinary design tool can be used to embed downstream processes for conceptual design and evaluation allowing simulation of life cycle properties. A knowledge enabled engineering approach was used to capture the engineering activities for design and evaluation of jet engine component flanges. For every design change, cost of manufacturing operations, maintenance and performance aspects can be directly assessed. The design tool assures that the engineering activities are performed accordingly to company design specification which creates a better control over the process quality. It also creates a better understanding enabling the engineers to optimize the concept in real time from an overall product life cycle view. The new tool will be the base for optimize the total product system and will be used not only between companies but also between product development departments in large global companies.