In a groundbreaking stride towards manufacturing innovation, the McNair Center's adept researchers have taken a leap into the future by harnessing digital transformation's power. Their target? The Lynx Automated Fiber Placement (AFP) Machine. Their objective for this research program came from discussing the challenges of legacy equipment within South Carolina's local manufacturing environment. Legacy systems, while cherished for their longevity, lack the cutting-edge features that define modern production. This prompted the question: How could these systems be upgraded to offer enhanced processes and operator advantages?
The solution, borne from the McNair Center's commitment to innovation, is an end-to-end system. This system adeptly collects, assesses, and presents pivotal process insights to machine operators. Each AFP machine element, from axes to the fiber placement head and Heraeus Humm3 heating system, is sampled at a rate of milliseconds. This real-time data fuels a machine learning model that predicts defects once each AFP course concludes. The model's role is pivotal, detecting anomalies and defects during the intricate layup process. This ensures manufacturing consistency. The model's findings aren't restricted to complex code and reports; they're relayed to machine operators via an augmented reality (AR) dashboard. This intuitive interface bridges machine intelligence and human intuition, effectively resolving any detected issues before production progresses. The AR dashboard is more than a communication conduit; it's a live window into the manufacturing process. Operators can visualize real-time data, detect trends, and log defects using the AR glasses' camera. This level of transparency empowers both novice and experienced operators to make informed decisions.
Recognizing the gradual nature of expertise, the McNair Center's team devoted significant resources to crafting a virtual reality training arena. This immersive simulation trains new operators in manufacturing and maintenance procedures on the AFP Machine. Safety remains paramount; this training approach ensures newcomers learn without compromising processes or safety. The impacts of this research venture extend beyond the McNair Center. With minor tweaks, the insights gained can seamlessly enhance other manufacturing equipment, uplifting processes across sectors.
Project Goals
- Equip legacy manufacturing machines with new cutting-edge technology to reduce need of purchasing new equipment.
- Develop Virtual reality training regime to expedite the training of new AFP operators.
- Improve human – machine interactions through collected data and augmented reality dashboards.