Browse Topic: Assembling
The segment manipulator machine, a large custom-built apparatus, is used for assembling and disassembling heavy tooling, specifically carbon fiber forms. This complex yet slow-moving machine had been in service for nineteen years, with many control components becoming obsolete and difficult to replace. The customer engaged Electroimpact to upgrade the machine using the latest state-of-the-art controls, aiming to extend the system's operational life by at least another two decades. The program from the previous control system could not be reused, necessitating a complete overhaul.
This SAE Aerospace Standard (AS) defines the requirements for a convoluted polytetrafluoroethylene (PTFE) lined, metallic reinforced, hose assembly suitable for use in aerospace fluid systems at temperatures between -65 °F and 400 °F for Class 1 assembly, -65 °F and 275 °F for Class 2 assembly, and at operating pressures per Table 1. The use of these hose assemblies in pneumatic storage systems is not recommended. In addition, installations in which the limits specified herein are exceeded, or in which the application is not covered specifically by this standard, shall be subject to the approval of the procuring activity.
Since the early 1980s, the automotive industry has used hydraulically actuated (servo-hydraulic) test systems to simulate operating speeds and road conditions for testing OEM components and fully assembled vehicles. They have helped unlock vast improvements in the quality, safety, and reliability of the cars and trucks coming off the world’s assembly lines.
Spot welds are integral to automotive body construction, influencing vehicle performance and durability. Spot welding ensures structural integrity by creating strong bonds between metal sheets, crucial for maintaining vehicle safety and performance. It is highly compatible with automation, allowing for streamlined production processes and increased efficiency in automotive assembly lines. The number and distribution of spot welds directly impact the vehicle's ability to withstand various loads and stresses, including impacts, vibrations, and torsion. Manufacturers adhere to strict quality control standards to ensure the integrity of spot welds in automotive production. Monitoring spot weld count and weld quality during manufacturing processes through advanced inspection techniques such as Image processing by YOLOv8 helps identify the number of spots and quality that could compromise safety. Automating quality control processes is paramount, and machine vision offers a promising
When asked about the most dreaded tasks on the manufacturing floor, many teams point to sanding, grinding, or polishing. These unforgiving tasks can be tedious, time-consuming, and hazardous, leading to respiratory illnesses and repetitive motion injuries. In today’s economic climate, finding workers willing to perform these taxing jobs can be challenging. Yet, they are often necessary when assembling metal, composite, or other parts into manufactured products.
When deploying robots in an industrial setting, one of the primary goals is performance. In an industrial robot workcell, performance is often measured as cycle time: the time required to complete a set of tasks. Typical tasks include painting, welding, and inspecting. Regardless of the tasks, the goal is to complete them as fast as possible, so that the workcell can begin work on the next set of tasks. A long cycle time for a given cell can cause that cell to become the bottleneck on an assembly line.
A team of researchers from Heidelberg University and Max Planck Institute for Medical Research have created a new technology to assemble matter in 3D. Their concept uses multiple acoustic holograms to generate pressure fields with which solid particles, gel beads, and even biological cells can be printed. These results pave the way for novel 3D cell culture techniques with applications in biomedical engineering.
In an air brake system, compressed air is used as an energy medium for braking applications, ensuring a good seal between the components is critical. The sealing performance of gaskets are significant for the product with joint features as it affects functionality and can cause a breakdown of the entire system; hence, finite element simulation of the sealing performance of gaskets is important for any product development. To simulate fluid interacting with gasket, a fluid-structure interaction (FSI) simulation is necessary by co-simulating a computation fluid dynamics (CFD) and finite element analysis (FEA) solvers to capture complex behavior of seal deformation under dynamic conditions during leakage, but it is a time-consuming process. In this article, the sealing performance of gaskets is studied in detail only till the start of leakage. It is not necessary to simulate the dynamic behavior of the seal beyond leakage to validate the sealing performance; hence, static nonlinear
The vehicle instrument panel (IP) system has several interactions with the surrounding components such as the Dash, Cowl, Cross Car Beam (CCB), Floor, Body Side etc. With such interactions comes different loadings, usage scenarios, interfaces and design challenges to overcome. For the specific case of the IP to Cowl & Dash interfaces, the position and performance in different load cases, such as, but not limited to, vibration and heat expansion loading as well as the assembly process. A design solution is required to enhance the performance in all these scenarios while maintaining the cost, weight & complexity as low as possible. This paper describes the development process of an optimized solution with a multi-disciplinary approach using advanced computer aided engineering (CAE) optimization tools, which involved performance in multiple virtual evaluations and mass. The achieved enhanced solution provides of multiple alternatives from early design stages to allow flexibility in the
The making of a quilt is an interesting process. Historically, a quilt is a canvas of work made from old pieces of cloth cut into squares or whatever shape that make a nice connected pattern and then stitched together. The quilt could be random pieces that is not related to each other. In most recent years and more common cases, a quilt is made of different pieces of patches that are connected and laid out in a special way to tell a story. Not only does it portray a story that is put together in a certain sequence, but it also stiches the pieces of the quilt into a nice and complete narrative. A story that one can understand just by looking at the quilt spread and unfolded. Much like the making of a quilt that has a story to tell, a Product Digital Quilt will tell the story of a product. The Digital Product Quilt replaces the conventional way of telling a product story. The traditional product story is a method that is serially connecting multiple product life cycle silos together
BMW's Munich factory remains the fertile root of a century of manufacturing, including its first R32 motorcycle in 1923. At the Munich plant - flanked by the engine-shaped “four-cylinder” headquarters tower and futuristic BMW Welt museum and customer-delivery center - BMW recently showed media its reimagined “iFactory.” This lean, green and digitized environment can build ICE, hybrid, electric or even hydrogen fuel-cell models on a single assembly line. That master plan includes a car and battery factory in Debrecen, Hungary, that BMW claims will be the industry's first CO2-emissions-free plant in 2025, fed entirely by photovoltaic or other renewable electricity.
NASA Langley Research Center has an improved method for making composite structures. Industrial composite manufacturing is primarily accomplished through three methods: co-cure, co-bond, and secondary bond processes. Co-cure produces predictable structures and joint properties but is costly and challenging to implement on large, complex structures. Co-bond and secondary bond processes have greater applicability to complex structures but produce unpredictable material interfaces and properties. The AERoBOND technology presents a method for manufacturing composites at scale with the reliability of co-cure in a bonded assembly process.
The scope of this document is related to the particular needs of oxygen equipment with regards to packaging and transportation. The document provides guidance for handling chemical, gaseous and liquid oxygen equipment. It summarizes national and international regulations to be taken into account for transportation on land, sea and air and provides information on classification of hazardous material. The aim of this document is to summarize information on packaging and transportation of oxygen equipment. Statements and references to regulations cited herein are for information only and should not be considered as interpretation of a law. Processes to maintain cleanliness of components and subassemblies during processing and assembly or storage of work-in-progress are outside the scope of this document. Guidance on this can be obtained from ARP1176. Rules for transportation and shipment do not cover oxygen equipment installed in an interior monument, e.g., galley unit or in a fuselage
Using the Box Behnken experimental design, this research work gives a thorough mathematical model for predicting the effects of drilling parameters on the delamination factor during the drilling of CFRP/Al stacked composites. These composites are commonly utilized in aerospace applications and are frequently subjected to drilling for assembling purpose. The goal of this study is to predict the drilling parameters like drill type, drill diameter, feed rate and spindle speedthat affect the amount of delamination which occurs when drilling such composites. During the drilling operation, damage was noticed on the surface of the fabricated composite laminates. The experiments were conducted according to the Box Behnken experimental design and delamination response is measured by using an image processing software. It is concluded that among all the parameters, the feed rate influences more on the delamination factor.
The world is moving from a manual workforce to a collaborative workforce in industrial production systems where humans and robots work together making the manufacturing process harmonious. Humans consist of characteristics like flexibility, adaptability, decision-making skills, and creativity while strength, endurance, speed, and accuracy are from robots. A combined workforce of a human and a robot provides more efficiency, flexibility, and increment in production. This paper compares a manual assembly and a collaborative assembly of ten flange assemblies. The assembly defined here is the joining of a circular cover plate and a flange using four bolts and nuts. A voice-assisted system is incorporated into the collaborative robot which picks the necessary assembly parts when prompted thus boosting the performance. The study begins by completing ten flange assemblies by a single person and noting the outcomes after completion of assembly. The time taken and the elemental motions are the
SAE J2461 specifies the recommended practices of a Vehicle Electronics Programming Stations (VEPS) architecture.in a Win32® environment. This system specification, SAE J2461, was a revision of the requirements for Vehicle Electronics Programming Stations (VEPS) set forth in SAE J2214, Vehicle Electronics Programming Stations (VEPS) System Specification for Programming Components at OEM Assembly Plants (Cancelled Jun 2004). The J2214 standard has been cancelled indicating that it is no longer needed or relevant.
As the world is moving from a manual workforce to a robot-based workforce, there is a huge scope for improved methods to make production lines more efficient. In this work, an effort is made to implement human-robot collaboration into an industrial process and is demonstrated with a flange assembly-line model. This paper explains how the Yolov4 algorithm was improved and fine-tuned to meet the requirements. A customized workspace was designed and manufactured to make the components more accessible. Different types of grippers were compared and the simplest and most efficient was then selected. Camera selection and calibration were done to get the RGB coordinates and the depth values which were finally converted into the robot's coordinate frame. The coordinates are then fed as the end goal position for the end effector to which the robot plans its motion and then executes. The paper also explains how the model responds to voice commands using the Google API to convert audio messages to
This SAE Aerospace Recommended Practice (ARP) provides processes for achieving the required cleanliness standards during the fabrication, assembly, and functional test of aircraft hydraulic systems. It covers exclusion and removal of solid and liquid contaminants from tubing during manufacture and final assembly, flushing of the installed system, and final checks to ensure cleanliness requirements are met.
For an enterprise, product quality is the foundation of its further development. Therefore, how to detect the quality of the products produced by the assembly line and accurately identify the problematic parts has become an increasingly concerned issue for enterprises. In this paper, we propose a novel quality detection model combining the latest YOLOv5 model and convolutional neural network, which can further improve the recognition precision and accuracy of YOLOv5 on the basis of its lightweight and high recognition efficiency. The proposed model can meet the needs of complex quality problems that are difficult to detect directly in assembly-line products. In the experiment, our model can detect the automotive dashboard and judge whether the cable buckle is connected in place. The accuracy of each buckle in the picture being correctly detected is more than 98%, the classification accuracy is also expected to reach 98%.
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