Design and Implementation of Intelligent Manufacturing Systems From Expert Systems, Neural Networks, to Fuzzy Logic PRENTICE HALL SERIES ON ENVIRONMENTAL AND INTELLIGENT MANUFACTURING SYSTEMS M. Jamshidi, Editor Volume 1: ROBOTICS AND REMOTE SYSTEMS FOR HAZARDOUS ENVIRONMENTS, edited by M. Jamshidi and P. J. Eicker. Volume 2: FUZZY LOGIC AND CONTROL: Software and Hardware Applkations, edited by M. Jamshidi, N. Vadiee, and T. J. Ross. Volume 3: ARTIFICIAL INTELLIGENCE IN OPTIMAL DESIGN AND MANUFACTURING, edited by Z. Dong. Volume 4: SOFT COMPUTING: Fuzzy Logic, Neural Networks, and Distributed Artificial Intelligence, edited by F. Aminzadeh and M. Jamshidi. Volume 5: NONLINEAR CONTROL OF ROBOTIC SYSTEMS FOR ENVIRONMENTAL WASTE AND RESTORATION, by D. Dawson, M. Bridges, and Z. Qu. Volume 6: DESIGN AND IMPLEMENTATION OF INTELLIGENT MANUFACTURING SYSTEMS: From Expert Systems, Neural Networks, to Fuzzy Logic, by H. R. Parsaei and M. Jamshidi Design and Implementation of Intelligent Manufacturing Systems From Expert Systems, Neural Networks, to Fuzzy Logic Editors Hamid R. Parsaei University of Louisville, USA M. Jamshidi University of New Mexico, USA For book and bookstore information Prentice Hall P T R http://www.prenhall.com gopher to gopher.prenhall.com Upper Saddle River, New Jersey 07458 Library of Congress Cataloging-in-Publication Data Design and implementation of intelligent manufacturing systems: from expert systems, neural networks, to fuzzy logic / editors Hamid R. Parsaei, Mo Jamshidi. p. cm. — (Prentice-Hall series on environmental and intelligent manufacturing systems) Includes bibliographical references (p.) and index. ISBN 0-13-458217-9 1. CAD/CAM systems 2. Manufacturing processes—Automation. 3. Expert systems (Computer science)—Industrial applications. I. Parsaei, H. R. II. Jamshidi, Mohammad. III. Series. TS155.6.D472 1995 670'.285-dc20 95-4068 CIP Editorial/production supervision: Patti Guerrieri Cover art: Aren Graphics Manufacturing buyer: Alexis R. Heydi Acquisitions editor: Bernard Goodwin Editorial assistant: Diane Spina ©1995 by Prentice Hall PTR Prentice-Hall Inc. A Pearson Education Company Upper Saddle River, NJ 07458 The publisher offers discounts on this book when ordered in bulk quantities. For more information, contact: Corporate Sales Department, Prentice Hall PTR, One Lake Street, Upper Saddle River, NJ 07458, Phone: 800- 382-3419, Fax: 201-236-7141, e-mail: [email protected] All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher. Printed in the United States of America 10 9 8 7 6 5 4 3 21 ISBN 0-13-458217-9 Prentice-Hall International (UK) Limited,London Prentice-Hall of Australia Pty. Limited, Sydney Prentice-Hall Canada Inc., Toronto Prentice-Hall Hispanoamericana, S.A., Mexico Prentice-Hall of India Private Limited, New Delhi Prentice-Hall of Japan, Inc., Tokyo Pearson Education Asia Pte. Ltd., Singapore Editora Prentice-Hall do Brasil, Ltda., Rio de Janeiro TO OUR FAMILIES Farah, Shadi, and Boback Jila, Ava, and Nima This page intentionally left blank TABLE OF CONTENTS Chapter 1. Workcell Programming Language for Intelligent Manufacturing Systems 1 A. Jana andD. M. Auslander Chapter 2. An Intelligent System for Automating the Inspection of Manufacturing Parts 19 M. D. Reimann andJ. Sarkis Chapter 3. An Intelligent Hybrid System for Synthesis and Control of a Metal Forming Process 39 A. F. Ali, C. A. Vassiliadis, J. S. Gunasekera R. Anbajagance andS. McDonald Chapter 4. Intelligent Diagnostics in Robotics and Integrated Manufacturing Systems 65 J. Graham andJ. Guan Chapter 5. Fuzzy Logic Controller for Part Routing 81 D. Ben-Arieh andE. S. Lee Chapter 6. Fuzzy-Logic Control as an Industrial Control Language for Embedded Controllers 107 S. Yeralan andB. Tan Chapter 7. Using Neural Networks for the Automatic Monitoring and Recognition of Signals in Manufacturing Processes 141 T. H. Hau andL. Lin vii viii Table of Contents Chapter 8. Artificial Neural Network Approach in Modeling of EDM and Wire-EDM Processes 161 G. Indurkhya, K. P. Rajurkar andR. Thautireddy Chapter 9. A Knowledge-Based Expert System for Selection of Industrial Robots 187 S. Shashikumar and A. K. Kamrani Chapter 10. A Case-Based Knowledge System to Trouble Shoot Failures in a Manufacturing Environment 211 E. C. Chung and C. A. Vassiliadis Chapter 11. Partially-overlapped Systems: the Scheduling Problem 241 M. KamelandH. Ghenniwa Chapter 12. An Object-Oriented Approach to Feature-Based Process Planning 275 J. M. Usher Chapter 13. Intelligent Feature Extraction for Concurrent Design and Manufacturing 301 J. Dong, H. R. Parsaei and A. Kumar Chapter 14. CAD in Automatic Machine Programming 325 B. O. Nnaji and T. S. Kang Chapter 15. Fault Diagnosis of Large Manufacturing Processes 359 W. O. Traxell, A. V. Huffaker and W. F. Maulsby AUTHOR INDEX 387 SUBJECT INDEX 389 Series Editor's Foreword The world communities, for the most part, are searching for ways to cooperate with each other in order to solve their emerging problems, which affects not only their own generation but future generations as well. The concerns about our environment, energy supplies (the shortage of them), water resources, food, and agriculture are some of the most urgent issues facing every nation of the world. These issues will need to be continuously dealt with in every conceivable form. This series was created three years ago to address the paramount issues of national economic security and respect for our environment (air, water, soil, lakes, etc.) and the emergence of artifi- cial intelligence as an integral attribute of today's and tomorrow's products. This series attempts to build two bridges. The first is between manufacturing and environment, making environmental issues an integral part of any manufacturing design process leading to environmentally friendly manufacturing systems. The second is between manufacturing and artificial intelligence, leading to what is now being called MIQ (Machine Intelligence Quotient Systems). Today, AI techniques of expert systems, fuzzy logic, neural networks, and evolutionary algorithms have found their ways, to different degrees, in a wide spectrum of manufactured products and manufacturing sys- tems. We invite concerned authors from all parts of the world and all walks of science, engineering, and technology to come forth with proposals for this series of books, with the above concerns as a motivating factor. Together we can disseminate the most relevant information to the world com- munity for the betterment of mankind. The current volume, superbly put together by Professor Hamid R. Parsaei of the University of Louisville, is a step toward our goal. This volume attempts to close the gap between AI and man- ufacturing. I would like to thank Professor Parsaei and all the fine authors of this volume for mak- ing a difference with their research and opening new avenues for future generations. Mohammad Jamshidi, Series Editor Prentice Hall Series on: Environmental and Intelligent Manufacturing Systems ix