Template framework for automated process routing

• US 8,914,141 B2
• Filed: 09/29/2010
• Issued: 12/16/2014
• Est. Priority Date: 10/02/2009
• Status: Active Grant

• Current Assignee: aPriori Technologies, Inc.
• Original Assignee: aPriori Technologies, Inc.
• Inventors: Philpott, Michael L., Rishel, Jeremy D., Gallaudet, Elisha, Gerlovin, Emmanuel
• Primary Examiner(s): ORTIZ RODRIGUEZ, CARLOS R
• Application Number:
  US12/893,247
• Publication Number:
  US 20110130855A1
• Time in Patent Office: 1,539 Days
• Field of Search: 700 28- 34, 700 47- 50, 700/99
• US Class Current: 700/99
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/32304 Minimize flow time, tact, shortest processing, machining time
• CPC Class Codes: G06Q 10/04 Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem" market predictions or forecasting for commercial activities G06Q30/0202

Abstract

A method and corresponding system is provided for determining an optimum manufacturing process routing. The method comprises electronically constructing a plurality of manufacturing process routings for a component to be manufactured. The electronically constructing for each manufacturing process routing of the plurality of manufacturing process routings comprises defining a recursive process routing tree for each manufacturing process routing, the recursive process routing tree comprising a plurality of nodes, each node of the plurality of nodes corresponding to a manufacturing process and comprising a branch node when the manufacturing process for a given node may be decomposed into a plurality of sub-processes for the given node. The method further comprises electronically determining an optimum process routing by evaluating each recursive process routing tree with reference to a cost for manufacturing the component to be optimized and determining the optimum process routing that minimizes the cost for manufacturing the component.

Claims

1. A method for determining an optimum manufacturing process routing, the method comprising:

electronically constructing a plurality of manufacturing process routings for a component to be manufactured, the electronically constructing for each manufacturing process routing of the plurality of manufacturing process routings comprising defining a recursive process routing tree for each manufacturing process routing, the recursive process routing tree comprising a plurality of nodes, each node of the plurality of nodes corresponding to a manufacturing process and comprising a branch node when the manufacturing process for a given node may be decomposed into a plurality of sub-processes for the given node, the electronically constructing being performed using at least one computer processor programmed to electronically construct the plurality of manufacturing process routings; and

electronically determining an optimum process routing of the plurality of manufacturing process routings by evaluating each recursive process routing tree for the plurality of manufacturing process routings with reference to a cost for manufacturing at least one geometric cost driver with reference to a geometric model of the component and determining the optimum process routing that minimizes the cost for manufacturing the component, the electronically determining being performed using the at least one computer processor, the at least one computer processor being further programmed to electronically determine the optimum process routing;

the evaluating each recursive process routing tree comprising expanding a component template into a plurality of process routing alternatives, and expanding and evaluating a geometric cost driver template for each geometric cost driver of the component; and

the determining the optimum process routing comprising applying a cost model and being based on component inputs including the geometric model and non-geometric manufacturing inputs that affect the cost of manufacturing the component.

2. A method according to claim 1, wherein at least one recursive process routing tree comprises at least one node corresponding to an optional manufacturing process.

3. A method according to claim 1, wherein at least one recursive process routing tree comprises at least one node corresponding to a repeated manufacturing process.

4. A method according to claim 1, wherein the electronically constructing the plurality of manufacturing process routings comprises defining a recursive process routing tree for each manufacturing process routing defined in a hierarchical routing template specification and evaluating the feasibility of each node of each recursive process routing tree for each manufacturing process routing, the defining the recursive process routing tree for each manufacturing process routing and the evaluating the feasibility of each node being performed by the at least one computer processor, the at least one computer processor being further programmed to electronically define the recursive process routing tree and to electronically evaluate the feasibility.

5. A method according to claim 4, wherein the evaluating the feasibility comprises evaluating each recursive process routing tree in a depth-first fashion and discarding a portion of each recursive process routing tree rooted at a given node when the given node is found to be infeasible, the evaluating the feasibility being performed by the at least one computer processor, the at least one computer processor being further programmed to electronically evaluate the feasibility.

6. A method according to claim 1, wherein the electronically determining an optimum process routing of the plurality of manufacturing process routings by evaluating each recursive process routing tree for the plurality of manufacturing process routings comprises:

(i) performing a post-order traversal of each recursive process routing tree to determine a cost for each recursive process routing tree, the performing the post-order traversal comprising determining a cost of each child node of each given node to derive the cost of the given node from the costs of the given node'"'"'s one or more child nodes; and

(ii) selecting a lowest cost recursive process routing tree for the plurality of manufacturing process routings;

the electronically determining an optimum process routing being performed by the at least one computer processor, the at least one computer processor being further programmed to electronically determine an optimum process routing.

7. A method according to claim 1, wherein the recursive process routing tree for each manufacturing process routing comprises a plurality of viable processes for manufacturing the component and a plurality of viable manufacturing operations to be performed as part of the plurality of viable processes.

8. A method according to claim 1, further comprising:

electronically determining an optimum number of times to perform a repeated manufacturing process, the electronically the optimum number of times being performed using the at least one computer processor, the at least one computer processor being further programmed to electronically determine the optimum number of times.

9. A method according to claim 8, wherein the electronically determining the optimum number of times to perform the repeated manufacturing process is performed using a plurality of electronic rules governing precedence and compatibility of processes within the repeated manufacturing process, the electronically determining the optimum number of times being performed using the at least one computer processor, the at least one computer processor being further programmed to electronically determine the optimum number of times.

10. A method according to claim 1, wherein the geometric cost driver is selected from the group consisting of number of holes, number of edges and type of bend.

11. A method according to claim 1, wherein the geometric cost driver is selected from the group consisting of perimeter, volume, and surface area.

12. A method according to claim 1, wherein the geometric model is a computer-aided design.

13. A method according to claim 1, wherein the non-geometric manufacturing inputs comprise at least one of production volume, years of production, location of manufacturing of the component, and materials.

14. A system for determining an optimum manufacturing process routing, the system comprising at least one computer processor, the at least one computer processor including:

a routing generation system programmed to electronically construct a plurality of manufacturing process routings for a component to be manufactured, the electronically constructing for each manufacturing process routing of the plurality of manufacturing process routings comprising defining a recursive process routing tree for each manufacturing process routing, the recursive process routing tree comprising a plurality of nodes, each node of the plurality of nodes corresponding to a manufacturing process and comprising a branch node when the manufacturing process for a given node may be decomposed into a plurality of sub-processes for the given node; and

a routing evaluation system programmed to electronically determine an optimum process routing of the plurality of manufacturing process routings by evaluating each recursive process routing tree for the plurality of manufacturing process routings with reference to a cost for manufacturing at least one geometric cost driver with reference to a geometric model of the component and determining the optimum process routing that minimizes the cost for manufacturing the component;

the routing evaluation system being further programmed to;

expand a component template into a plurality of process routing alternatives, and expand and evaluate a geometric cost driver template for each geometric cost driver of the component; and

apply a cost model based on component inputs including the geometric model and non-geometric manufacturing inputs that affect the cost of manufacturing the component.

15. A system according to claim 14, wherein at least one recursive process routing tree comprises at least one node corresponding to an optional manufacturing process.

16. A system according to claim 14, wherein at least one recursive process routing tree comprises at least one node corresponding to a repeated manufacturing process.

17. A system according to claim 14, wherein the routing generation system comprises a system programmed to electronically construct the plurality of manufacturing process routings by a process comprising defining a recursive process routing tree for each manufacturing process routing defined in a hierarchical routing template specification and evaluating the feasibility of each node of each recursive process routing tree for each manufacturing process routing.

18. A system according to claim 17, wherein the evaluating the feasibility comprises evaluating each recursive process routing tree in a depth-first fashion and discarding a portion of each recursive process routing tree rooted at a given node when the given node is found to be infeasible.

19. A system according to claim 14, wherein the routing evaluation system comprises a system programmed to electronically determine an optimum process routing of the plurality of manufacturing process routings by evaluating each recursive process routing tree for the plurality of manufacturing process routings by a process comprising:

(i) performing a post-order traversal of each recursive process routing tree to determine a cost for each recursive process routing tree, the performing the post-order traversal comprising determining a cost of each child node of each given node to derive the cost of the given node from the costs of the given node'"'"'s one or more child nodes; and

(ii) selecting a lowest cost recursive process routing tree for the plurality of manufacturing process routings.

20. A system according to claim 14, wherein the recursive process routing tree for each manufacturing process routing comprises a plurality of viable processes for manufacturing the component and a plurality of viable manufacturing operations to be performed as part of the plurality of viable processes.

21. A system according to claim 14, further comprising:

a repeat processing system programmed to electronically determine an optimum number of times to perform a repeated manufacturing process.

22. A system according to claim 21, wherein the repeat processing system is further programmed to electronically determine the optimum number of times to perform the repeated manufacturing process using at least a plurality of electronic rules governing precedence and compatibility of processes within the repeated manufacturing process.

23. A system according to claim 14, wherein the geometric cost driver is selected from the group consisting of number of holes, number of edges and type of bend.

24. A system according to claim 14, wherein the geometric cost driver is selected from the group consisting of perimeter, volume, and surface area.

25. A system according to claim 14, wherein the geometric model is a computer-aided design.

26. A system according to claim 14, wherein the non-geometric manufacturing inputs comprise at least one of production volume, years of production, location of manufacturing of the component, and materials.