Browse Topic: Manufacturing systems
Aerospace engine components like discs, blisks and rings are engineered to perform in extreme operating environments. They need to withstand intense heat and stress and be as lightweight as possible to meet exacting specifications. These parts are also notoriously difficult to machine, and manufacturers who work with them must meet serious challenges of their own. Holding tight tolerances, maintaining predictable tool life and accounting for internal material stress relief from material removal can be especially difficult when profiling complicated features such as thin-walled flanges, undercut pockets and seal fins
Nowadays, Hybrid Electric Vehicles (HEVs) and Electric Vehicles (EVs) are becoming popular globally due to increasing pollution levels in the environment and expensive conventional non-renewable fuels. Li-ion battery EV’s have gained attention because of their higher specific energy density, better power density and thermal stability as compared to other cell chemistries. Performance of the Li-ion battery is affected by temperatures of the cells. For Li-ion cells, optimum operating temperature range should be between 15-35 °C [1]. Initially, small battery packs which are cooled by air were used but nowadays, large battery packs with high power output capacities being used in EV’s for higher vehicle performance. Air based cooling system is not sufficient for such batteries, hence, liquid coolant based cooling systems are being introduced in EV’s. Computational Fluid Dynamics (CFD) simulation can be used to get better insight of cell temperature inside battery. But it is complex, time
The automotive industry faces unprecedented regulatory and societal pressure to adopt sustainable manufacturing practices. A recent survey by Accenture shows that more than 34 percent of today’s largest manufacturers have committed to zero-emission goals, yet 93 percent of them will miss their targets unless they double their emission reduction rates by 2030
The changing regulatory landscape and innovation of medical products is driving an interest in additional options for medical product sterilization. One nontraditional way manufacturers can sterilize medical products that is becoming increasingly popular is with sterilizers that use vaporized hydrogen peroxide (VH2O2). The publication of ISO 22441:2022 and its recognition by the United States Food and Drug Administration (US FDA), coupled with the FDA’s reclassification of VH2O2 sterilization as an Established Category A process in 2024, supports this modality of sterilization
Sustainability remains a dominant trend in packaging and processing, continuing to attract the attention of the life sciences industry and inspire its new initiatives. Although pharmaceutical and medical device manufacturers must prioritize patient safety and product protection, concerns about climate change, greenhouse gas (GHG) emissions, plastic waste, and pressure to move toward a circular economy are prompting a greater focus on improving the sustainability of their products and packaging
Wysong USA has been manufacturing industrial press brakes, hydraulic shears, and mechanical shears for sheet metal and plastics for nearly 120 years. Like many companies, their motto was “if it ain’t broke, don’t fix it,” so their product had remained essentially the same. But during a customer visit that motto clashed with another company saying, “the customer is always right.” This customer had replaced the dry clutch brake for an oil shear clutch brake that was more accurate. “The customer is always right” won, so Wysong updated their product line and increased accuracy while reducing costs, making it a win all around
Continental's Georg Fässler, executive chair of the 2024 SAE COMVEC, details efforts to future-proof forthcoming vehicles. Severe driver shortages, rising fuel and material costs, escalating demand for freight transport, higher sustainability requirements - there is no shortage of challenges facing the transport sector. Commercial vehicle manufacturers and industry suppliers are devoting significant resources to develop, test and bring to market the technological advances that will help alleviate these pressure points. “The digitalization of commercial vehicles and the whole logistics chain is a necessary response and one of the most important developments in the CV industry in my view,” said Continental Automotive's head of commercial and special vehicles, Georg Fässler, in a recent interview with SAE International
Airplane manufacturers running noise tests on new aircraft now have a much cheaper option than traditional wired microphone arrays. And it’s sensitive enough to help farmers with pest problems. The wireless microphone array that one company recently created with help from NASA can locate crop-threatening insects by listening for sound they make in fields. And now, it’s making fast, affordable testing possible almost anywhere
Squeak and rattle (SAR) noise audible inside a passenger car causes the product quality perceived by the customer to deteriorate. The consequences are high warranty costs and a loss in brand reputation for the vehicle manufacturer in the long run. Therefore, SAR noise must be prevented. This research shows the application and experimental validation of a novel method to predict SAR noise on an actual vehicle interior component. The method is based on non-linear theories in the frequency domain. It uses the Harmonic Balance Method (HBM) in combination with the Alternating Frequency/Time Domain Method (AFT) to solve the governing dynamic equations. The simulation approach is part of a process for SAR noise prediction in vehicle interior development presented herein. In the first step, a state-of-the-art linear frequency-domain simulation estimates an empirical risk index for SAR noise emission. Critical spots prone to SAR noise generation are located and ranked. In the second step, the
The global medical device market offers opportunities for innovation-driven growth. Demand for smart, new lifesaving and life-enhancing technologies is perhaps stronger than ever. Manufacturers around the world looking to capitalize on this eager global market face a long list of challenges — some big, some small. Supply-chain disruptions, labor shortages, rising materials costs, and other headwinds are leading to delays in both engineering and manufacturing processes. Despite these challenges, the world demands medical device manufacturers’ best. A surging geriatric population, implications of a global pandemic, and the mortality rates for heart disease, cancer, obesity, and other conditions are all contributing to strong and sustained market demand. One study predicts a compound annual growth (CAGR) of 5.4 percent will push global sales of medical devices to nearly $658 billion (USD) by 2028. Of course, the road to success will be littered with familiar roadblocks — and some that are
For years, expertise in terrestrial applications has served as a launchpad for innovation. Companies honed their skills by building the networks that connected us on earth, but now, eyes are turning skyward. By adapting their capabilit ies to the unique demands of non-terrestrial applications, these same players are unlocking new possibilities and rewriting the rules of communication beyond the atmosphere. Here, Dan Rhodes, Director of Business Development at designer and manufacturer of RF-to-mmWave components and subsystems, Filtronic, explores the bridge between terrestrial expertise and non-terrestrial ambitions, highlighting how terrestrial success is becoming the fuel for stellar solutions. Bridging the terrestrial and non-terrestrial worlds is not merely a matter of applying existing technologies to a new canvas. While both environments share fundamental principles of communication and rely on robust components such as transmitters, receivers, filters and amplifiers, the shift
The pace of innovation in automotive and heavy-duty transportation is rapidly accelerating. Manufacturers are harnessing advancements in electrification and electronification, ushering in new levels of safety, comfort, infotainment, connectivity, performance, and sustainability
The transition towards battery electric vehicles (BEVs) has increased the focus of vehicle manufacturers on energy efficiency. Ensuring adequate airflow through the heat exchanger is necessary to climatize the vehicle, at the cost of an increase in the aerodynamic drag. With lower cooling airflow requirements in BEVs during driving, the front air intakes could be made smaller and thus be placed with greater freedom. This paper explores the effects on exterior aerodynamics caused by securing a constant cooling airflow through intakes at various positions across the front of the vehicle. High-fidelity simulations were performed on a variation of the open-source AeroSUV model that is more representative of a BEV configuration. To focus on the exterior aerodynamic changes, and under the assumption that the cooling requirements would remain the same for a given driving condition, a constant mass flow boundary condition was defined at the cooling airflow inlets and outlets. A parametric
The context for real-world emissions compliance has widened with the anticipated implementation of EU7 emissions regulations. The more stringent emissions limits and deeper real-world driving test fields of EU7 make compliance more challenging. While EU6 emissions legislation provided clear boundaries by which vehicle and powertrain Original Equipment Manufacturers (OEMs) could develop and calibrate against, EU7 creates additional challenges. To ensure that emissions produced during any real-world driving comply with legal limits, physical testing conducted in-house and in-field to evaluate emissions compliance of a vehicle and powertrain will not be sufficient. Given this, OEMs will likely need to incorporate some type of virtual engineering to supplement physical testing. In this respect, the HORIBA Intelligent Lab virtual engineering toolset has been created and deployed to produce empirical digital twins of a modern light-duty electrified gasoline Internal Combustion Engine (ICE
Just as NASA needs to reduce mass on a spacecraft so it can escape Earth’s gravity, automotive manufacturers work to reduce weight to improve vehicle performance. In the case of brake rotors, lighter is better for a vehicle’s acceleration, reliable stopping, and even gas mileage. Orbis Brakes Inc. licensed a NASA-patented technology to accomplish that and more. This revolutionary brake disc design is at least 42 percent lighter than conventional cast iron rotors, with performance comparable to much more expensive carbon-ceramic brakes
As manufacturers push for increased productivity, low-value tasks such as material transport have become clear targets for improvement. In efforts to reduce material transport in large facilities, companies have explored the use of intermediate warehouse areas throughout the production floor. However, this takes up valuable space, requires additional material processing and handling, and creates opportunities for errors and lost or misplaced materials
Some people do not go the dentist for a fear of syringes, thereby risking a worsening of untreated tooth damage. However, some dental practices offer patients a gentle alternative — a device for computer-controlled, pain-free local anesthesia, which its developers fittingly call a magic wand: The Wand – STA System from Milestone Scientific. For the past 25 years, the U.S.-based company specializing in injection technology has been manufacturing the system’s single-use components from CYROLITE®- by Röhm — a high-quality, transparent, acrylic-based plastic especially for medical applications
CES 2024 offers a busy look at the software-definied-vehicle future. For a technology set to define our automotive future for years to come, it's surprising that not everyone in the industry can agree on what a software-defined vehicle actually is. It's not controversial to say that SDVs need to be able to adjust - or define - some aspect of a vehicle's performance through software. It's the outer limits of how this works that can prove challenging to define
Medical devices are becoming smaller and smaller, and the need for advanced material solutions keeps growing. There’s also a critical call for manufacturers to adhere to stringent regulations while improving device functionality. Through our deep understanding and application of fundamental chemistry, Chemours materials have emerged as effective alternatives — helping innovators in the medical industry achieve continued success across medical device design
Demand for electrically driven vehicles has increased significantly in recent years, due to its subsidized rate, economical operation and environmentally friendly features. If discussed about India, the sales have increased by 174% in a single year. This drastic jump in sales has encouraged the current automobile manufacturers to come up with more and more electric-driven vehicle platforms in a crunch time frame. And to fulfill these requirements, manufacturers have to work a lot to introduce new technologies like E-axle, which can be space effective, less expensive and easy to assemble. But the introduction of such new technologies brings an even bigger requirement for new validation methodologies, and in the case of electric vehicles (EV) where the development time has been very less, as brought a bigger challenge of more dependency on virtual simulation. As the operational procedure of E-axles is completely different from the conventional axles, the loads that are coming will also
Thermoplastic resins, composites, and copolymers can help the healthcare industry address multiple sustainability challenges. Specifically, thermoplastic materials can help manufacturers develop medical devices that
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