Manufacturability analysis and optimisation of a reconfigurable machine to enhance optimal machine performance

Reconfigurable machines (RM's) are machines that have been designed with a system architecture to quickly respond to the constantly changing needs of various industries, as well as to manage product variations within a certain part family. However, the reconfigurable systems structure and related modules bring new challenges for design, manufacturing and maintenance which ultimately affects the overall performance and productivity of these machines. To address this, the intelligent use of sensors to enable real-time data monitoring and analysis was explored. To further assist with the optimal management and decision-making of the best possible manufacturing process, a comprehensive manufacturing study of the machine was carried out. This leads to increased production capabilities, improved product quality, reduced maintenance requirements, and lower costs. This study describes the design optimisation and manufacturability analysis of a reconfigurable machine using intelligent sensing techniques based on a case study of a reconfigurable vibrating screen (RVS) machine. Using CompactRIO (NI cRIO-9074) with a total of 6 channels, analysis of the different sub-systems of the RVS machine was performed. The results of the study showed that the design and the manufactured prototype is able to withstand failure on the different subsystem under different loading conditions. This research contributes to the development of reconfigurable machines and also prediction of the structural integrity of such machines using smart sensoring techniques in order to prevent unforeseen failures and enhance optimal machine performance.