The project is to design and implement: 1) CNC machine control simulator systems to enhance the cognitive learning aspects of online laboratories; and 2) simulator interfaces for metrology and quality control systems to enhance the cognitive learning aspects of online labs. Project activities also include improving and re-developing seven current industrial training modules covering High Speed CNC machining, prototyping, machine tool calibration, precision metrology, offline and online quality control, remote monitoring and supervision of machining and robotic assembly processes, and quality assurance and computer aided design/machining (CAD/CAM).
The proposed project will advance knowledge and understanding of student learning in laboratory experience that combines actual and virtual components and is delivered both in person/on location and through the Internet. The model has the potential to transform the training process for the workforce in various sectors, regardless of their location, to meet the needs of the relevant industries. Existing knowledge about student learning serves as a base upon which the project activity is built, along with experiences in a pilot version of one of the proposed labs in which students reported a high level of verisimilitude in the lab exercises. The commitment to sustain the project after the end of NSF funding comes from both the institution and industry partners.
The training model has the potential to significantly lower training costs in precision-manufacturing. The project will increase the number of students and graduates in mechanical and industrial technology programs to meet the industry's demand for a skilled workforce.
One of the key objectives in durable goods-manufacturing is to create faster industrial processes throughput by eliminating the need for off-line quality control and part inspection. Nowadays, as automation, high performance machining and labor savings are introduced in machining of discrete component prototyping and manufacturing, it is also desirable to reduce the inspection time and manpower, having an intelligent real-time quality control of the products. This is typically performed by using coordinate measuring machines (CMMs) and related inspection tools. Great savings of both time and labor during the inspection process can be realized in the machining of discrete components through such approaches and practices. The major goals and objectives of this project is to integrate strategic process optimization concepts and intelligent controls in high speed machining, creative thinking and solutions-based applications, machine tool calibration, on-machine quality control, precision metrology applications into the existing engineering curriculum through the development and implementation of learning modules that will simulate industry approach to product development cycle that is design, analysis, prototyping and improvement into selected required coursework in each engineering discipline. The outcomes of the project are: 1) Facilitate student exposure to potential careers in the area of manufacturing technology and CNC as well as overcoming precision metrology skills shortages by incorporating current advances in CNC technology and engineering metrology into the undergraduate/adult learning environment with an emphasis placed in the laboratory activities and projects that will simulate innovative design, design analysis and process simulation, prototyping and improvement cycle. 2) Using Project Centered Learning (PCL) pedagogy in the learning modules, students will develop skills to confront ambiguity and uncertainty as expected and integral part of the solving engineering problems. Through the developed and implemented experimental settings during this project, we engaged the students in both on-site and online/remote laboratory experiments, although this endeavor is just in its initial phase. The next phase is related to the development and implementation of a computer-based CNC (Computer Numerical Control) simulators, software applications, as well as exemplary associated learning modules. Virtual, remote or hands-on laboratories are critical in terms of engineering education; each has its advantages and disadvantages. Virtual labs offer cost savings and active learning, but they are not real and present limited opportunities for trial and error. Remote labs provide real experiments with real equipment at lower cost but lack the "feel" of handling real equipment and can be less engaging. Onsite labs offer hands-on experience and problem-solving opportunities but are costly, less flexible and fail to provide access and ease of use for the disabled and distance learners. However, in the literature is suggested that a "mixture of elements might be superior to any single technology." A key aspect of our project is the use and improvement of the onsite Engineering Laboratory with the High Speed CNC components, enhancing the student lab experiences, allowing them to perform real industrial laboratory experiments and tasks that both reinforce and assess what they’ve learned in their virtual lab studies in less time and with less risk than would normally be present. Our strategy based on virtual-labs-to-onsite-labs approach is focused on increasing the students’ efficiency while performing physical laboratory activities by shifting the center of attention towards the learning objectives of the laboratory rather than on "how to do the laboratory." A derived, but nonetheless important objective is to improve and re-develop seven current industrial training modules covering High Speed CNC machining, prototyping, machine tool calibration, precision metrology, offline and online quality control, remote monitoring and supervision of machining and robotic assembly processes, quality assurance and computer aided design/machining (CAD/CAM). This activity is currently undergoing, its progress being highlighted in the sections below. The CNC simulators used during this project provide realistic operation, part programming and maintenance environment at a fraction of the current cost. This is done by using a real CNC hardware, therefore significantly lowering training costs. We developed industry-supplied and coordinated projects, as well as capstone projects for collaborative student teams. The newly-equipped laboratories are networked for cross-institutional use between Drexel University and affiliated community colleges. The heart of this project is the hardware and software simulators as well as a newly purchased CNC Turning Center and quality control tools.
