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Paul K. Wright
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Proceedings Papers
Proc. ASME. IMECE2001, Manufacturing Engineering, 11-17, November 11–16, 2001
Paper No: IMECE2001/MED-23301
Abstract
Micro-machining by mechanical machine tool, or micro mechanical machining, is an emerging fabrication technology that broadens applicable material ranges including metals and plastics. One of the problems in this micro machining, however, is relatively large run-out which is comparable to the diameter of tools. A series of experiments were conducted to identify Total Indicator Reading (TIR) and dynamic run-out of micro-machining on aluminum workpieces. Results presented in this paper indicate the ratio of run-out to tool diameter ranged between 2.2% and 10%. To compensate for the run-out in the design stage of micro features, a Java-based Design for Manufacturing (DFM) tool was developed. This tool can assist designers to design micro channels accurately considering the effect of run-out. Furthermore, the feasibility of micro-injection molding was examined with micro-machined channels. Micro-molded parts were made from ABS plastic showing negligible shrinkage from the molding process.
Proceedings Papers
Proc. ASME. DETC95, Volume 1: 21st Design Automation Conference, 17-24, September 17–20, 1995
Paper No: DETC1995-0003
Abstract
Most consumer or commercial electronic products are electromechanical systems consisting of mechanical components such as structures, enclosures, driving systems and mechanisms, combined with electrical components such as printed circuit boards (PCBs), power supply, wires (harness) and switches. The design of such multidisciplinary products involves high coordination and cooperation between the two different engineering fields of mechanical and electrical design. However, in spite of the advancements of CAD tool development in design automation technology within each field, a gap still exists for good communication between the designers in these two fields during the course of the design. This gap makes the design process of such products time-consuming and error prone. This paper describes a research effort that facilitates multidisciplinary concurrent design for consumer electronic products. The focus is on how to integrate mechanical and electrical CAD tools into a more flexible and extensible concurrent design environment to share and communicate critical design information during the design process. A multidisciplinary concurrent design environment based on the CAD framework concept is described. Approaches for integrating the design data and information in such a multidisciplinary design environment are discussed. A prototyping system for the concurrent design of consumer electronic products is also presented.
Proceedings Papers
Proc. ASME. CIE95, ASME 1995 15th International Computers in Engineering Conference and the ASME 1995 9th Annual Engineering Database Symposium, 131-146, September 17–20, 1995
Paper No: CIE1995-0740
Abstract
Most consumer or commercial electronic products are electro-mechanical systems consisting of mechanical components such as structures, enclosures, driving systems and mechanisms, combined with electrical components such as printed circuit boards (PCBs), power supply, wires (harness) and switches. The design of such multidisciplinary products involves high coordination and cooperation between the two different engineering fields of mechanical and electrical design. However, in spite of the advancements of CAD tool development in design automation technology within each field, a gap still exists for good communication between the designers in these two fields during the course of the design. This gap makes the design process of such products time-consuming and error prone. This paper describes a research effort that facilitates multidisciplinary concurrent design for consumer electronic products. The focus is on how to integrate mechanical and electrical CAD tools into a more flexible and extensible concurrent design environment to share and communicate critical design information during the design process. A multidisciplinary concurrent design environment based on the CAD framework concept is described. Approaches for integrating the design data and information in such a multidisciplinary design environment are discussed. A prototyping system for the concurrent design of consumer electronic products is also presented.
Proceedings Papers
Proc. ASME. DETC-CIE96, Volume 1: Design for Manufacturing Conference, V001T01A024, August 18–22, 1996
Paper No: 96-DETC/DFM-1286
Abstract
Within the Integrated Design And Manufacturing Environment (IMADE), operation planning provides a mapping from geometric design primitives to machining operation sequences for manufacturing processes. Operation planning includes tool selection, machining parameter selection, and tool path generation. An object oriented approach to program structure is adopted, whereby features, operations and tools, inherit behaviors and attributes from the appropriate class-hierarchies for the part, the manufacturing operations, and tooling classes. A detailed example is presented illustrating the operation planning search algorithm. Scripts are generated by the individual machining operations for execution on a machine tool. Tooling information is maintained in an object-oriented database through the FAR libraries for Common LISP. Examples of particular process plans show that the inherent trade-offs between specified precision and machining time can be investigated. An Open Architecture Machine Tool (MOSAIC-PM) has been used to machine the parts created by the feature based design and planning system. The novel contributions of this paper relate to the demonstration of “seamless” links between, a) design, b) planning, and c) actual fabrication by milling.
Proceedings Papers
Proc. ASME. DETC97, Volume 4: Design for Manufacturing Conference, V004T31A041, September 14–17, 1997
Paper No: DETC97/DFM-4336
Abstract
We describe a plastic injection mold making agent that is part of a domain unified computer-aided design environment. This environment enables concurrent design of the “to-be-molded” part, by facilitating communication between electrical and mechanical engineering CAD tools. Once the design is completed and certain constraints are satisfied, the design is passed to the mold making agent. After the designer inputs some mold parameters, the mold agent automatically determines the parting direction and parting plane, and generates the mold halves. This is achieved by applying a set of heuristic rules on the part geometry. These rules, design constraints, and methods used to generate the mold are discussed. Resulting mold halves have been fabricated on a 3 axis milling machine using CAD / CAPP / CAM tools described in this paper. Examples of aluminum molds and sample output from the mold making agent are presented.
Proceedings Papers
Proc. ASME. DETC98, Volume 6: 18th Computers in Engineering Conference, V006T06A036, September 13–16, 1998
Paper No: DETC98/CIE-5517
Abstract
New techniques in Information Technology are now changing not only our daily life, but also the professional practice of product design and manufacturing for new product development. Internet technology in particular opens up another domain for building future CAD/CAM environments. This environment will be a global, network-centric environment with various members providing different software tools, manufacturing facilities, and analysis services for distributed design and fabrication. In this paper, we first briefly describe a vision and current development in a distributed design and manufacturing environment. The paper then emphasizes how current CAD tools will evolve to facilitate the distributed design and fabrication process. In particular, the development of a set of Web-based design tools for fabricating parts using a machining process via the Internet is presented. Experiments on machining 2-1/2 D and freeform parts through this Java-based design tool have shown the feasibility for a networked machining service via the Internet.
Proceedings Papers
Proc. ASME. DETC99, Volume 2: 19th Computers and Information in Engineering Conference, 745-754, September 12–16, 1999
Paper No: DETC99/CIE-9082
Abstract
The paper establishes a set of machining rules for web-based manufacturing and discusses the guidelines for their classification and implementation. Rule checking is split into three levels, the Design Interface. Process Planning, and Machine Tool levels. Rules are placed in these different levels according the resources available and the inherent constraints of each level while maintaining their principle functionality. The implementation of rule checking on the CyberCut 3-D interface, a web-based manufacturing tool for machining, is discussed. The current implementation checks for the four most common conflicts between mechanical designers and manufacturing engineers.
Proceedings Papers
Proc. ASME. DETC99, Volume 4: 4th Design for Manufacturing Conference, 13-22, September 12–16, 1999
Paper No: DETC99/DFM-8938
Abstract
Inspired by MOSIS, the CyberCut project has been developing a manufacturing service for mechanical parts over the Internet. Among the various services provided by CyberCut, this paper will focus on the front end of the design process, in particular on the on-line CAD tool that the designers will be working with when defining the final geometry of a part to be fabricated with 3-axis milling. To date we have constructed two prototype versions of a design interface for CyberCut, called WebCAD, and tested them on audiences consisting mostly of students at Berkeley and at some sister institutions with research groups working on similar problems in design for machining. We learned that it is surprisingly difficult to create such a front end that will lead the designer to manufacturable design on 3-axis milling machine. We will discuss the results of these initial trials, and the insights gained from them, which then led to the specifications for WebCAD 1.5 which is currently nearing completion. We will discuss the simple and consistent view of the milling process that needs to be presented to the users of WebCAD, some of the key paradigms in the user interface, and the extra utilities that we had to incorporate into the WebCAD tool for users who have had no previous exposure to machining.
Proceedings Papers
Proc. ASME. IDETC-CIE2000, Volume 3: 5th Design for Manufacturing Conference, 25-38, September 10–13, 2000
Paper No: DETC2000/DFM-14015
Abstract
This work is motivated by a desire to put DfM on solid theoretical foundations. The paper evaluates measures of manufacturability and classes of DfM methods and frameworks independent of the specific manufacturing processes. Criteria used in evaluation include theoretical foundation, accuracy, flexibility in choosing utility/objective function, domain independence, ease of use, level and extent of information required, computational cost, ability to incorporate uncertainty and market factors. We introduce a DfM approach based on Benefit/Cost analysis. All design utilities are lumped into a single “ Design Benefit (R D ) ”, all manufacturability factors into another parameter “ Manufacturing Rating (R M ) ”, and then techniques of benefit-cost analysis and value engineering are used to make decisions about design improvements. Use of overall and marginal DfM ratings allows trade-offs to be made. Any set of desired objectives can be used for computing the ratings. It is also possible to incorporate design or manufacturing constraints.
Proceedings Papers
Proc. ASME. IDETC-CIE2000, Volume 3: 5th Design for Manufacturing Conference, 251-259, September 10–13, 2000
Paper No: DETC2000/DFM-14001
Abstract
The Reference Free Part Encapsulation (RFPE) is a workholding system which is designed to “free-up” the design space and greatly expand the possible range of the parts that can be designed and then machined. RFPE allows the machining of parts with thin spars and narrow cross-sections. Such parts are often difficult or impossible to hold with conventional vises or toe-clamps. Despite the increased capability of the RFPE technique, its influence on part warpage and part accuracy has not yet been sufficiently documented, and thus the experiments reported here have made a new contribution in this direction. 7075T6 aluminum (annealed) and ABS materials were machined with flat end mills, and deflections of the specimens were measured. The results were obtained in two categories i) without RFPE using conventional toe clamps ii) with RFPE. RFPE uses a bi-phase material (Rigidax™). In the conventional toe clamp set-up, the aluminum specimens showed increasing warpage with decreasing test-part dimension. When the molten fixturing material was applied, the warpage remained the same for the aluminum specimens. In the conventional toe clamp set-up, the ABS plastic showed almost no warpage after machining. However, warpage increased to a maximum of 0.04∼0.06 inch when the fixturing material was applied to the ABS specimens. The warpage is proposed to occur due to the relaxation of ABS’s anisotropic molecular chains during the heating and cooling process. In conclusion, warpage of thin aluminum parts was from machining-induced residual stress, but warpage of thin ABS parts was mainly from thermal residual stress developed during the RFPE process. Results presented in this paper indicate the amount of warpage that might be expected. These values could be used in CAD/CAM databases for DFM (Design For Manufacturing) checking.
Proceedings Papers
Proc. ASME. IMECE2009, Volume 12: Micro and Nano Systems, Parts A and B, 343-352, November 13–19, 2009
Paper No: IMECE2009-11636
Abstract
Wireless sensor networks (WSN) are a promising technology for ubiquitous, active monitoring in residential, industrial and medical applications. These nodes combine a radio transceiver, microcontroller and sensors into a low power package. A current bottleneck for widespread adoption of WSN’s is the power supplies. While the power demands can be somewhat alleviated through novel electronics, any primary battery will have a finite lifetime. Energy harvesting, from ambient vibration, light, and heat sources, offers an opportunity to significantly extend the lifetime of the nodes and possibly provide perpetual power. Thermal energy is an ideal source for WSNs due to the availability of low-grade ambient waste heat sources. Thermoelectric devices convert temperature gradients into DC electric power in compact form factors. Efficient device designs require hundreds of high-aspect ratio semi-conductor microelements fabricated electrically in series and thermally in parallel. This design requirement presents problems for standard microfabrication techniques due to thickness limitations of standard semiconductor processes. We present a new method of contact dispenser printing, specifically developed to additively create microscale generators. Initial materials performance results show promising results and are further detailed in this work.
Proceedings Papers
Proc. ASME. IMECE2009, Volume 8: Engineering to Address Climate Change; Sustainable Products and Processes, 185-190, November 13–19, 2009
Paper No: IMECE2009-12893
Abstract
This paper presents a prototype application for residential energy monitoring using a digital energy meter coupled with a wireless sensor. The current measuring meter is designed to be placed in-line with household appliances. The data are then sent using a wireless sensor node to a low cost server. The system allows end users to measure energy expenditure and visualize the data in real time with a forward prediction of cost for running the appliance. The system is an enabling technology for a global architecture of dynamic electricity pricing schemes and load reduction programs, called Demand Response. The new system allows residents to become self aware about power consumption levels in their home and enables users to make informed decisions about demand response events.
Proceedings Papers
Proc. ASME. IMECE2009, Volume 8: Engineering to Address Climate Change; Sustainable Products and Processes, 77-84, November 13–19, 2009
Paper No: IMECE2009-11674
Abstract
Traditional monitoring of current flow in power lines involves breaking the circuit for through-the-sensor type monitoring or separating individual wires for around-the-conductor “clamp” metering. Such techniques for measurement are invasive and disruptive for many applications. Using 0.9 cm diameter permanent magnets attached to piezoelectric bimorph elements in conjunction with the fluctuating magnetic fields generated by alternating currents, sensors have been developed that enable in-situ , self-powered measurement of current flow without the need to encircle or disconnect the wire being measured. Whereas previous development [1, 2] of these devices has focused on two-wire applications for low (<600V) voltages, single-wire configurations for higher-voltage (up to 15kV) applications are also considered here. Outputs have been found to be linear through a wide ranges of current (0–200A on 0.6–120V AC), with resolution limited primarily by sensor distance from the target wire (3cm or less from wire edge). Sensitivity studies have been performed on conductors of varying dimensions (18 gauge to 4 gauge) and geometries (single conductor and two-wire) for known sensor placements and current flows. Initial integration has been performed with a wireless radio device to produce a self-contained sensor package 8cm by 10cm by 3cm that can sample data at 2 kHz and transmit results to a base station for further analysis. Initial numerical modeling of the magnetic field gradients around current-carrying wires has been performed to optimize sensor placement. Potential applications include customer (home, business, industry) and distribution grid-level monitoring.
Journal Articles
Article Type: Technology Review
J. Comput. Inf. Sci. Eng. September 2008, 8(3): 034001.
Published Online: August 21, 2008
Abstract
Agile methods of software development promote the use of flexible architectures that can be rapidly refactored and rebuilt as necessary for the project. In the mechanical engineering domain, software tends to be very complex and requires the integration of several modules that result from the efforts of large numbers of programmers over several years. Such software needs to be extensible, modular, and adaptable so that a variety of algorithms can be quickly tested and deployed. This paper presents an application of the unified process (UP) to the development of a research process planning system called CyberCut. UP is used to (1) analyze and critique early versions of CyberCut and (2) to guide current and future developments of the CyberCut system. CyberCut is an integrated process planning system that converts user designs to instructions for a computer numerical control (CNC) milling machine. The conversion process involves algorithms to perform tasks such as feature extraction, fixture planning, tool selection, and tool-path planning. The UP-driven approach to the development of CyberCut involves two phases. The inception phase outlines a clear but incomplete description of the user needs. The elaboration phase involves iterative design, development, and testing using short cycles. The software makes substantial use of design patterns to promote clean and well-defined separation between and within components to enable independent development and testing. The overall development of the software tool took about two months with five programmers. It was later possible to easily integrate or substitute new algorithms into the system so that programming resources were more productively used to develop new algorithms. The experience with UP shows that methodologies such as UP are important for engineering software development where research goals, technology, algorithms, and implementations show dramatic and frequent changes.
Proceedings Papers
Proc. ASME. IDETC-CIE2004, Volume 4: 24th Computers and Information in Engineering Conference, 693-701, September 28–October 2, 2004
Paper No: DETC2004-57721
Abstract
Noise in vehicular automatic transmissions is a complex phenomenon involving several interacting factors. One of the contributing factors to noise for a single pair of meshing gears has been shown to be the transmission error. The transmission error (TE) is defined in terms of deviation of the speed ratio from the ideal speed ratio. It has since been hypothesized that the composite transmission error in a planetary system would be the key contributor to noise in automatic transmissions. This composite error would have to include the contributions from individual meshes and account for the configuration of the transmission system. This paper describes a design system that enables engineers to predict and study effects of parameter variation on the composite transmission error. The designer first specifies the configuration of the transmission using canonical graphs. The graph contains the elements such as gears, clutches and brakes of the transmission system as its nodes and the relationship among them for the edges. The design system uses the graph to solve for the speeds and torques. The transmission errors for the individual meshes are computed and then combined into the composite transmission error using a simple average.
Proceedings Papers
Proc. ASME. IDETC-CIE2003, Volume 2: 29th Design Automation Conference, Parts A and B, 843-852, September 2–6, 2003
Paper No: DETC2003/DAC-48790
Abstract
This paper presents a design methodology for the thermal design and packaging of hybrid electronic-mechanical products. In this work, tight integration between ECAD and MCAD was achieved through the use of a web-based tool used in managing the concurrent designs, called the Domain Unified CAD Environment (DUCADE). This work also reduced the amount of time required for thermal simulation by using a web-based Design of Experiment Testbed (DOET) to systematically determine effects of varying system parameters before full-scale computational fluid dynamics (CFD) thermal modeling was performed. The design process began by proper selection of material, manufacturing process and cooling methods, based on electrical and integrated circuit design. DUCADE was then set up to monitor couplings between the various domains. This was followed by computer-aided-design and computer-aided-engineering of the mechanical package. In computer-aided-engineering, DOET was first used to determine variables that had significant effect on the thermal system response. Detailed CFD thermal simulations were then carried out in FLOTHERM only focusing on variables that the DOET determined to have strong effect. Rapid prototypes were fabricated to refine the design before final production. Each step of the cycle was tested and demonstrated through a case study on the design of the Berkeley Emulation Engine (BEE) which involved multi-disciplinary electrical, mechanical, and thermal design.
Proceedings Papers
Proc. ASME. IDETC-CIE2002, Volume 3: 7th Design for Manufacturing Conference, 3-12, September 29–October 2, 2002
Paper No: DETC2002/DFM-34154
Abstract
This paper presents a case study on the mechanical design and fabrication of the Pico Radio Test Bed : a wireless networking node for experimentation with applications, networking, media access layer design, and position locating algorithms. Particular focus is placed on the systematic design process and resolving coupling design constraints between the mechanical and electrical domains. Three generations of the design are presented to demonstrate the evolution of the design as conflicts arose, problems were noticed, and requirements changed.
Proceedings Papers
Proc. ASME. IDETC-CIE2002, Volume 1: 22nd Computers and Information in Engineering Conference, 553-559, September 29–October 2, 2002
Paper No: DETC2002/CIE-34475
Abstract
Significant cycle time saving can be achieved in 2.5-D milling by intelligently selecting tool sequences. The problem of finding the optimal tool sequence was reduced to finding the shortest path in a single-source single-sink directed acyclic graph. The nodes in the graph represented the state of the stock after the tool named in the node was done machining and the edges represented the cost of machining. In this paper a novel method for handling tool holder collision in the graph-based algorithm for optimal tool sequence selection has been developed. The method consists of iteratively solving the graph for the shortest path, validating the solution by checking for tool holder collisions and eliminating problematic edges in the graph. Also described is a method to intelligently build the graph such that in presence of tool holder collisions, the complexity of building the graph is greatly reduced.
Proceedings Papers
V. Sundararajan, Daniel Antonetti, Paul K. Wright, Sameer Gudal, Shounak Athavale, Yong Pan, Shuh-Yuan Liou
Proc. ASME. IDETC-CIE2005, Volume 5b: Power Transmission and Gearing Conference, 929-936, September 24–28, 2005
Paper No: DETC2005-85497
Abstract
Noise generated in automotive transmissions can cause annoyance to passengers and can affect customer satisfaction. This noise may be a result of complex interactions between the transmission, the vehicle body and driving conditions and is thus very difficult to analyze. A good starting point however is to assume that the transmission noise is due to transmission error in the gears. Besides being amenable to mathematical analysis, research has shown that transmission error is indeed a major factor of noise for a pair of meshing gears. This assumption has however not been tested or extended to epicyclic gear systems that are widely used in vehicular automatic transmissions. We present here a design consultant that allows the designer to configure various transmissions, specify various input parameters and study the effect of parameter variations and errors on the overall transmission error. We build upon our previous work by presenting detailed implementation issues in the development of such systems.
Proceedings Papers
Proc. ASME. IMECE2002, Microelectromechanical Systems, 487-496, November 17–22, 2002
Paper No: IMECE2002-39309
Abstract
Advances in low power VLSI design, along with the potentially low duty cycle of wireless sensor nodes open up the possibility of powering small wireless computing devices from scavenged ambient power. Low level vibrations occurring in typical household, office, and manufacturing environments are considered as a possible power source for wireless sensor nodes. This work focuses on the design of electrostatic vibration-to-electricity converters using MEMS fabrications technology. Detailed models of three different design concepts are developed. The three design concepts are evaluated and compared based on simulations and practical considerations. A formal optimization of the preferred design concept is performed, and a final design is produced using the optimal design parameters. Simulations of the optimized design show that an output power density of 116 μW/cm 3 is possible from input vibrations of 2.25 m/s 2 at 120 Hz. Test devices have been designed for a Deep Reactive Ion Etching (DRIE) process that etches MEMS structures into the top layer of a Silicon On Insulator (SOI) wafer. The devices are currently being fabricated.
Topics:
Vibration
