Browse Topic: Manufacturing systems
Safety improvements in vehicle crashworthiness remain a primary concern for automotive manufacturers due to the increasing complexity of traffic and the rising number of vehicles on roads globally. Enhancing structural integrity and energy absorption capabilities during collisions is paramount for passenger protection. In this context, longitudinal rails play a critical role in vehicle crashworthiness, particularly in mitigating the effects of rear collisions. This study evaluates the structural performance of a rear longitudinal rail extender, characterized by a U-shaped, asymmetric cross-section, subjected to rear-impact scenarios. Seventy-two finite-element models were systematically developed from a baseline configuration, exploring variations in material yield conditions, sheet thickness, and targeted geometric modifications, including deformation initiators at three distinct positions or maintaining the original geometry. Each model was simulated according to ECE R32 regulation
As I'm wont to do come December, with work well underway on the first issue of the new year, I like to take stock of upcoming venues for innovative product reveals and thought-provoking presentations on emerging trends and technologies. Come the first week of January, that means CES in Las Vegas. Traditional equipment manufacturers have increasingly used the event to demonstrate to the broader public that they not only deal in metal but also the digital realm. For example, earlier this year at CES, John Deere revealed its second-generation tech stack featuring camera pods, Nvidia Orin purpose-built processors and Deere's VPUs (vision processing units), along with four new autonomous machines including the 9RX 640 tractor for open-field ag operations. The company is exhibiting again this coming year.
When manufacturers seek to leverage specialized expertise, advanced processing capabilities, or proprietary technologies without assuming the financial burden of acquiring and maintaining dedicated equipment or facilities, they often turn to toll processing.
In this Q&A, Audrey Turley, director of lab operations – biosafety at Nelson Laboratories, spoke with Medical Design Briefs about the critical importance of monitoring and managing material changes in medical devices. Even seemingly minor shifts — such as switching suppliers or altering processing steps — can introduce unknown additives or variations that impact biocompatibility and, ultimately, patient safety. Turley discusses how manufacturers can effectively document and justify changes, maintain regulatory compliance, and strengthen supplier relationships to ensure ongoing device safety. She also shares insights into trends shaping post-pandemic supply-chain strategies and the growing emphasis on proactive risk assessment and communication across the product lifecycle.
As advanced technologies reshape the medical device landscape, the demands placed on contract manufacturers are evolving. Today’s partners are expected to do more than deliver components — they must anticipate disruptions, adapt quickly, and bring a level of technical and strategic depth that supports faster development without compromising quality.
Over the past 25 years, the heavy fabrication and construction equipment industry has experienced significant transformation. Driven by a global surge in demand for construction machinery, manufacturers are under increasing pressure to deliver higher volumes within shorter timelines and at competitive costs. This demand surge has been compounded by workforce-related challenges, including a declining interest among the new generation in acquiring traditional manufacturing skills such as welding, heat treatment, and painting. Furthermore, the industry faces difficulties in staffing third-shift operations, which are essential to meet production targets. The adoption of automation technologies in heavy fabrication and construction equipment manufacturing has been gradual and often hindered by legacy product designs that were optimized for conventional manufacturing methods. As the industry transitions toward smart, connected manufacturing environments under the industry 4.0 paradigm, it
In today’s competitive landscape, industries are relying heavily on the use of warranty data analytics techniques to manage and improve warranty performance. Warranty analytics is important since it provides valuable insights into product quality and reliability. It must be noted here that by systematically looking into warranty claims and related information, industries can identify patterns and trends that indicate potential issues with the products. This analysis helps in early detection of defects, enabling timely corrective actions that improve product performance and customer satisfaction. This paper introduces a comprehensive framework that combines conventional methods with advanced machine learning techniques to provide a multifaceted perspective on warranty data. The methodology leverages historical warranty claims and product usage data to predict failure patterns & identify root causes. By integrating these diverse methods, the framework offers a more accurate and holistic
The Operator’s Field of Vision (FOV) test, conducted in accordance with IS/ISO 5006:2017, is a vital assessment to ensure the safety and operational comfort of personnel operating Construction Equipment Vehicles (CEVs) / Earth-Moving Machinery. IS/ ISO 5006:2017 defines rigorous guidelines for evaluating the operator’s visibility from the driver's seat, with particular emphasis on the Filament Position Centre Point (FPCP), determined from the Seat Index Point (SIP) coordinates. The test includes assessment of masking areas, focusing on the Visibility Test Circle (a 24-meter diameter ground-level circle around the machine), and on the Rectangular Boundary on which a vertical test object is placed at a height specific to the machine type and its operating mass. These parameters are designed to simulate real-world operating conditions. This paper introduces a portable testing setup developed specifically for conducting the Operator’s FOV test as per IS/ISO 5006:2017. The setup facilitates
Direct current (DC) systems are increasingly used in small power system applications ranging from combined heat and power plants aided with photovoltaic (PV) installations to powertrains of small electric vehicles. A critical safety issue in these systems is the occurrence of series arc faults, which can lead to fires due to high temperatures. This paper presents a model-based method for detecting such faults in medium- and high-voltage DC circuits. Unlike traditional approaches that rely on high-frequency signal analysis, the proposed method uses a physical circuit model and a high-gain observer to estimate deviations from nominal operation. The detection criterion is based on the variance of a disturbance estimate, allowing fast and reliable fault identification. Experimental validation is conducted using a PV system with an arc generator to simulate faults. The results demonstrate the effectiveness of the method in distinguishing fault events from normal operating variations. The
Noise generated by a vehicle’s HVAC (Heating, Ventilation, and Air Conditioning) system can significantly affect passenger comfort and the overall driving experience. One of the main causes of this noise is resonance, which happens when the operating speed of rotating parts, such as fans or compressors, matches the natural frequency of the ducts or housing. This leads to unwanted noise inside the cabin. A Campbell diagram provides a systematic approach to identifying and analyzing resonance issues. By plotting natural frequencies of system components against their operating speeds, Test engineers can determine the specific points where resonance occurs. Once these points are known, design changes can be made to avoid them—for example, adjusting the blower speed, modifying duct stiffness, or adding damping materials such as foam. In our study, resonance was observed in the HVAC duct at a specific blower speed on the Campbell diagram. To address this, we opted to optimize the duct design
Why smart electrical distribution is the new frontier in sustainable manufacturing. From transitioning to renewable energy, embracing the circular economy and pursuing carbon offsets, today's automakers are actively working to become more sustainable. Many OEMs have big goals to become fully carbon-neutral by 2050. Some believe they can get there even earlier. But look past the cars and sources of energy right into the factories in which the vehicles of today and tomorrow are born and focus on a key question: how can carmakers make significant strides inside their plants to cut waste and improve sustainability?
Like those in many other industries, truck and off-highway vehicle manufacturers face the challenge of producing quality components and maintaining productive processes while also generating a better bottom line. Improving employee training, simplifying complex operations and implementing better workflows can all help generate efficiencies. While not a new concept, lightweighting - in this case, reducing the weight of parts through the substitution of traditional steel with high-strength, thinner steels - can also be a viable answer to a better vehicle. As a rule of thumb, when manufacturers double the strength of the material through lightweighting, it is possible to reduce the weight of the part by one-third. That weight reduction can then lower the cost per part for greater profitability per piece of equipment and greater annual savings.
Celebrating its 35th year, the National Aerospace Defense Contractors Accreditation Program (Nadcap) continues to advance quality assurance and regulatory compliance for aviation, defense, and space OEMs and suppliers. This article summarizes how Nadcap accreditation works, its benefits for manufacturers, and its role in expanding additive manufacturing through industry-wide consensus. The Nadcap program was first established in 1990 by a small group of aerospace and defense OEMs. Their goal was to create an accreditation initiative that provides a common approach to auditing the manufacturing and production processes used by companies supplying parts, components, structures, and services to major aerospace and defense OEMs. This foundation set the stage for Nadcap's continued focus on quality assurance and regulatory compliance in the industry.
As automotive manufacturers have tried to set themselves apart by reducing emissions, and increasing vehicle range/fuel economy by eliminating any energy loss from inefficiencies on the vehicle, the brake corners have been an area of interest to reduce off-brake torque to zero in all conditions. Caliper designers can revise some attributes like piston seal grooves, and pad retraction features to reduce drag, but even if a caliper is designed perfectly in all aspects, trying to measure it in a reliable and repeatable manner proves to be difficult. There are many ways to measure brake drag all with ranging complexity. Some of the simplest measurements are the most repeatable, but it excludes the majority of the vehicle inputs. The most vehicle representative testing requires the most complex equipment and comes with the most challenges. This paper will focus mainly on the different ways residual brake drag can be measured, the benefits and challenges to each of them, the problems trying
Aerospace research and development (R&D) is at a turning point. Emerging technologies promise faster and more efficient systems, but also expose deep limitations in aging infrastructure, siloed processes, and manual workflows. The growing disconnect between technological advances and the physical and organizational infrastructures that support them creates a bottleneck to industry progress. Electric actuation, advanced automation, and software-driven testing are becoming the norm, challenging manufacturers to adapt without disrupting operational stability. Navigating this tension requires strategic investments, flexible design thinking, and a willingness to break from legacy approaches that can no longer support the innovations driving the industry forward.
This document applies to the development of Plans for integrating and managing electronic components in equipment for the military and commercial aerospace markets, as well as other ADHP markets that wish to use this document. Examples of electronic components described in this document include resistors, capacitors, diodes, integrated circuits, hybrids, application specific integrated circuits, wound components, and relays. It is critical for the Plan owner to review and understand the design, materials, configuration control, and qualification methods of all “as-received” electronic components and their capabilities with respect to the application; and to identify risks and, where necessary, take additional action to mitigate the risks. The technical requirements are in Section 3 of this standard and the administrative requirements are in Section 4.
Over the past 30 years concerns about noise & vibration have become more critical in the design and manufacture of the automobile. Tools, both in physical testing and computer aided engineering have and continue to develop permitting more refined designs. Today’s customer can be very discerning when it comes to vehicle noises and vibrations. However, this is not a new concern for automotive customers or manufactures. This paper highlights the drive from automotive manufacturers to promote quiet, smooth and vibrationless operation of their products as well as some of the advances in vehicle component design over the past 100+ years. This is not an exhaustive study, but rather the intent is to bring to light the long history of noise and vibration in the automotive industry and its importance to the customers even in the infancy of the auto industry.
There is an increasing effort to reduce noise pollution across different industries worldwide. From a transportation standpoint, pass-by regulations aim to achieve this and have been implementing increasingly stricter emissions limits. Testing according to these standards is a requirement for homologation, but does little to help manufacturers understand why their vehicles may be failing to meet limits. Using a developed methodology such as Pass-by Source Path Contribution (SPC, also known as TPA) allows for identification of dominant contributors to the pass-by receivers along with corresponding acoustic source strengths. This approach is commonly used for passenger vehicles, but can be impractical for off-highway applications, where vehicles are often too large for most pass-by-suitable chassis dynamometers. A hybrid approach is thereby needed, where the same techniques and instrumentation used in the indoor test are applied to scenarios in an outdoor environment. This allows for
Large eddy simulations (LES) of two HVAC duct configurations at different vent blade angles are performed with the GPU-accelerated low-Mach (Helmholtz) solver for comparison with aeroacoustics measurements conducted at Toyota Motor Europe facilities. The sound pressure level (SPL) at four near-field experimental microphones are predicted both directly in the simulation by recording the LES pressure time history at the microphone locations, and through the use of a frequency-domain Ffowcs Williams-Hawking (FW-H) formulation. The A-weighted 1/3 octave band delta SPL between the two vent blades angle configurations is also computed and compared to experimental data. Overall, the simulations capture the experimental trend of increased radiated noise with the rotated vent blades, and both LES and FW-H spectra show good agreement with the measurements over most of the frequency range of interest, up to 5,000Hz. For the present O(30) million cell mesh and relatively long noise data collection
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