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Implementation of Reconfigurable Manufacturing Systems in the Manufacturing of Turbo Charger Turbine Housing

Turbo Energy Private Ltd-Murugan Vanamurthy
Turbo Energy Private Ltd.-Kumaran Aravindh, Kumaran Arun
Published 2019-10-11 by SAE International in United States
Today manufacturing industries have become more competitive and to survive, industries should be capable of accommodating the sudden market change. The conventional manufacturing systems like Dedicated Manufacturing Lines (DMLs) can produce high volume of product but difficult to cater to varying product types. On the other hand, Flexible Manufacturing System (FMS) is capable of handling product variety but not suited for mass production, The Reconfigurable Manufacturing System (RMS) gives the advantage of both the system, as it has the capability to adjust to both high volume requirement and product variety, and it able to upgrade to new process technology with minimal effort. In this work the reconfiguration is carried out in machine and system level. At machine level, a new inspection machine is proposed which can be used for multiple products with minimal adjustments and a special drilling and bore tool is suggested to reduce the cycle time and ramp up time when product changes. At system level a new layout is proposed which can handle multiple products effectively and which requires less space compared…
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A Framework for Effective Implementation of Process Failure Modes and Effects Analysis with Control Plans to Mitigate Process, Discrete Manufacturing and Service Industries, Using Aerospace Standard Best Practices

GITAM School of Technology-Mani Rathinam Rajamani, Eshwaraiah Punna
Published 2019-10-11 by SAE International in United States
In Today’s World, Every Manufacturing and Service Industry aims in providing the Highest Quality of Products and Service at the lowest Competitive Cost and timely delivery to its Customers. The Discrete Aerospace Manufacturing and Assembly industry is taking initiatives to implement the Process Failure Modes and Effects Analysis (PFMEA) tool for its critical Aerospace Manufacturing and Assembly suppliers, by implementing Aerospace Standards, in an effort to create a synergy between the End user customers, Original Equipment manufacturers and the suppliers, for ensuring increased safety, quality, reliability for the Aircraft parts and components produced by them. The main aim is to use this concept as a Process Risk Management tool for Identification, Assessment, Mitigation, Control and Prevention of risks associated with Designs and Manufacturing. This method is quite different from conventional FMEA methodology as it focuses on an integrated approach of linking the process flow diagram, followed by a PFMEA again linked with a Control plan to identify and implement controls for measuring and monitoring the process risks. This can identify the manufacturing system’s area of…
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High-Speed 3D Printer for High-Performance Plastics

  • Magazine Article
  • TBMG-35262
Published 2019-10-01 by Tech Briefs Media Group in United States

3D printers that build small parts layer by layer from melted plastic can take up to an hour to produce a pocket-sized piece. This process is far too slow for the mass-production of components as required by the automotive industry, for instance.

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A New Approach for Development of a High-Performance Intake Manifold for a Single-Cylinder Engine Used in Formula SAE Application

SAE International Journal of Engines

VIT University, India-Thangavel Venugopal, Routray Anubhav
  • Journal Article
  • 03-12-04-0027
Published 2019-07-26 by SAE International in United States
The Formula SAE (FSAE) is an international engineering competition where a Formula style race car is designed and built by students from worldwide universities. According to FSAE regulation, an air restrictor with circular cross section of 20 mm for gasoline-fuelled and 19 mm for E-85-fuelled vehicles is to be incorporated between the throttle valve and engine inlet. The sole purpose of this regulation is to limit the airflow to the engine used. The only sequence allowed is throttle valve, restrictor and engine inlet. A new approach of combining Ram theory and acoustic theory methods are investigated to increase the performance of the engine by designing an optimized intake runner for a particular engine speed range and an optimized plenum volume in this range. Engine performance characteristics such as brake power, brake torque and volumetric efficiency are taken into considerations. Ricardo WAVE simulation software is used to evaluate the impacts of plenum volume and runner length on engine performance based on the afore-mentioned performance characteristics. Various intake manifold designs are iterated in accordance with the surface…
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Mixture Distributions in Autonomous Decision-Making for Industry 4.0

SAE International Journal of Materials and Manufacturing

Oakland University, USA-Christopher Slon, Vijitashwa Pandey, Sam Kassoumeh
  • Journal Article
  • 05-12-02-0011
Published 2019-05-29 by SAE International in United States
Industry 4.0 is expected to revolutionize product development and, in particular, manufacturing systems. Cyber-physical production systems and digital twins of the product and process already provide the means to predict possible future states of the final product, given the current production parameters. With the advent of further data integration coupled with the need for autonomous decision-making, methods are needed to make decisions in real time and in an environment of uncertainty in both the possible outcomes and in the stakeholders’ preferences over them. This article proposes a method of autonomous decision-making in data-intensive environments, such as a cyber-physical assembly system. Theoretical results in group decision-making and utility maximization using mixture distributions are presented. This allows us to perform calculations on expected utility accurately and efficiently through closed-form expressions, which are also provided. The practical value of the method is illustrated with a door assembly example and compared to traditional random assembly methods and results.
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Development of an Emergency Stop Assist System

Toyota Motor Corp.-Kazuhiro Morimoto, Masato Takagi, Takashi Oda
Tri-AD-Masaki Takano, Naoki Nishimura
Published 2019-04-02 by SAE International in United States
Social concern with traffic accidents caused by driver’s medical emergencies has been growing for the last several years. In Japan, the government issued technical guidelines in June 2016 to promote systems that deal with such accidents. Based on those guidelines, the Emergency Stop Assist system was manufactured in October 2017 to help reduce such accidents. This article first describes its purpose and core design, then presents an overview of the system, and finally discusses its effectiveness.
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Metal 3D Printing for Complex Heat Exchangers

  • Magazine Article
  • TBMG-34154
Published 2019-04-01 by Tech Briefs Media Group in United States

Renishaw West Dundee, IL

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Mobile Laser Trackers for Aircraft Manufacturing: Increasing Accuracy and Productivity of Robotic Applications for Large Parts

FFT Produktionssysteme GmbH & Co KG-Fabian Ehmke
Fraunhofer IFAM-Christoph Brillinger, Till Staude, Kevin Deutmarg, Maximilian Klemstein, Christian Boehlmann
Published 2019-03-19 by SAE International in United States
The demand for higher production rates of large parts in aircraft industry requests more flexible manufacturing solutions. High-accurate mobile robots show a promising alternative in comparison with high-invest special machines. With mobile robot-based solutions processes can be executed simultaneously which increases the productivity significantly. However, the freedom of mobility results in insufficient positioning accuracy of these machines. Hence fast and accurate referencing processes are required to achieve cost-effectiveness and meet production tolerances. In this publication a Mobile Laser Tracker (MLT) system and a holistic approach for future manufacturing systems with mobile robots will be introduced and discussed.
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Demonstration of Transformable Manufacturing Systems through the Evolvable Assembly Systems Project

University of Nottingham-David Sanderson, Alison Turner, Emma Shires, Jack Chaplin, Svetan Ratchev
Published 2019-03-19 by SAE International in United States
Evolvable Assembly Systems is a five year UK research council funded project into flexible and reconfigurable manufacturing systems. The principal goal of the research programme has been to define and validate the vision and support architecture, theoretical models, methods and algorithms for Evolvable Assembly Systems as a new platform for open, adaptable, context-aware and cost effective production. The project is now coming to a close; the concepts developed during the project have been implemented on a variety of demonstrators across a number of manufacturing domains including automotive and aerospace assembly. This paper will show the progression of demonstrators and applications as they increase in complexity, specifically focussing on the Future Automated Aerospace Assembly Phase 1 technology demonstrator (FA3D). The FA3D Phase 1 demonstrated automated assembly of aerospace products using precision robotic processes in conjunction with low-cost reconfigurable fixturing supported by large volume metrology. This was underpinned by novel agent-based control for transformable batch-size-of-one production. The paper will conclude by introducing Phase 2 of the Future Automated Aerospace Assembly Demonstrator - currently in development - that…
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Aircraft Deicing Vehicle - Self-Propelled

G-12E Equipment Committee
  • Aerospace Standard
  • ARP1971D
  • Current
Published 2019-02-13 by SAE International in United States
This SAE Aerospace Recommended Practice (ARP) covers requirements for a self-propelled, boom-type aerial device, equipped with an aircraft deicing/anti-icing fluid spraying system. The unit shall be highly maneuverable for deicing all exterior surfaces of commercial aircraft, of sizes agreed upon between purchaser and manufacturer, in accordance with AS6285. The vehicle shall be suitable for day and night operations.
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