Fusion of product and process data: Batch-mode and real-time streaming

In today's DP product realization enterprise it is imperative to reduce the design-to-fabrication cycle time and cost while improving the quality of DP parts (reducing defects). Much of this challenge resides in the inherent gap between the product and process worlds. The lack of seamless, bi-directional flow of information prevents true concurrency in the product realization world. This report addresses a framework for product-process data fusion to help achieve next generation product realization. A fundamental objective is to create an open environment for multichannel observation of process date, and subsequent mapping of that data onto product geometry. In addition to the sensor-based observation of manufacturing processes, model-based process data provides an important complement to empirically acquired data. Two basic groups of manufacturing models are process physics, and machine kinematics and dynamics. Process physics addresses analytical models that describe the physical phenomena of the process itself. Machine kinematic and dynamic models address the mechanical behavior of the processing equipment. As a secondary objective, an attempt has been made in this report to address part of the model-based realm through the development of an open object-oriented library and toolkit for machine kinematics and dynamics. Ultimately, it is desirable to integrate design definition, with all types of process data; both sensor-based and model-based. Collectively, the goal is to allow all disciplines within the product realization enterprise to have a centralized medium for the fusion of product and process data