Browse Topic: Production
This study carefully designed and successfully developed a mechanical voltage stabilizing control device. The device uses silicone oil as the key component material of the liquid spring and 1Cr13 as the main material of the pressure control unit, enhancing its high-pressure resistance (up to 35 MPa), oxidation resistance, and acid-alkali corrosion resistance. By optimizing the transmission mechanism and simplifying the pressure regulation module, the device achieves a pressure regulation range of 0.1–21 MPa with an accuracy of ±0.01 MPa, significantly broader and more precise than traditional devices. To address manufacturing challenges, advanced CNC machine tools, ceramic cutting tools, and optimized heat treatment processes (e.g., quenching and tempering) were adopted, ensuring component machining accuracy within ±0.02 mm. Field applications in 13 oil wells demonstrated a 15.6% increase in daily oil production (from 25.5 t/d to 29.5 t/d) and a 17.9% increase in daily gas production (from 2800 m^3/d to 3300 m^3/d), with stable casing pressure control at 5.3 MPa. The device has created 1.225 million yuan in economic benefits while eliminating safety hazards, providing critical technical support for efficient and environmentally friendly oil and gas production.
Aircraft assembly systems, as a critical phase in aerospace manufacturing, face significant challenges in maintaining production efficiency and ensuring product quality. This complex manufacturing system exhibits two distinct characteristics: (1) tightly coupled interactions among manufacturing elements involving process sequences, material flows, and equipment utilization; and (2) dynamic resource allocation and material distribution plans. The inherent variability in production element configurations often leads to operational instability and schedule deviations, which may result in abnormal production states. To address these challenges, this study proposes a data-driven predictive framework that integrates Long Short-Term Memory (LSTM) neural networks with multi-criteria evaluation. The developed LSTM-based model effectively forecasts two critical production indicators of cycle time and balance rate, achieving temporal prediction through historical operational data analysis. The proposed methodology facilitates timely anomaly detection and early warning, allowing proactive risk mitigation and ensuring sustained production system stability. This research contributes to advancing intelligent monitoring and control strategies for aircraft assembly operations within data-driven manufacturing environments.
Additive manufacturing (AM) processes facilitate the production of components with high geometrical complexity, presenting substantial opportunities for innovation in demanding sectors such as aerospace and biomedical engineering. A significant challenge impeding their broader application is the characteristic surface roughness of as-fabricated parts, which results from the layer-wise construction and the presence of partially melted powder particles. While electrochemical polishing (EP) represents a viable post-processing technique for achieving a smooth surface finish, a comprehensive understanding of how the non-equilibrium microstructures characteristic of AM materials interact with the EP process remains incomplete. This investigation centers on the electrochemical polishing behavior of Ti-6Al-4V alloy fabricated by direct energy deposition (DED), utilizing a sodium chloride-ethylene glycol electrolyte. The findings reveal that the material's distinct engenders anisotropic anodic dissolution. This behavior is attributed to the differential electrochemical potentials among the constituent phases and their crystallographic orientations, which consequently narrows the operational process window for effective, uniform polishing. This preferential dissolution of certain phases results in the formation of a subtle, micro-scale topographical variation that mirrors the orientation of the original columnar grain structure. Notwithstanding this microstructural influence, the EP treatment proved highly successful in refining the surface finish, substantially decreasing the average surface roughness from 0.350 μm to 0.042 μm. Concurrently, the treatment led to a significant enhancement in the alloy's corrosion resistance, attributed to an oxide layer. These findings underscore the critical necessity of accounting for microstructural characteristics when developing optimized electrochemical polishing protocols for additively manufactured components.
In this paper, we focus on satellite production lines and design and implement a digital twin simulation and verification system for them. This is to improve manual documentation efficiency and provide sufficient process controllability in the small satellites’ batch production and assembly testing. We built a layered architecture. This allows the system to dynamically interact with AIT data management systems, structured process systems, and equipment data by fusing multi-source data. We also develop functional modules that combine lightweight 3D model visualization, dynamic simulation engines, and hybrid scheduling optimization algorithms. These modules can perform twin simulation, execute processes, intelligently schedule production, manage work reporting, conduct intelligent analysis, trigger anomaly alarms, and perform system management. We also dynamically simulate complex workflows like satellite transfer and automated assembly. These workflows are then verified using 3D virtual scene modeling and physical engines. We use time-series analysis to improve scheduling accuracy and multidimensional dynamic monitoring and hierarchical response to enhance production stability. In practice, the system can provide visualized control over the full process of satellite production. This greatly improves assembly efficiency and process controllability. It can also be an extensible digital way for aerospace manufacturing. The use of hierarchical architecture design and multimodal data fusion can be further applied in the complex equipment intelligent manufacturing.
Vehicle electrification and accelerated development cycles create a need for virtual Noise, Vibration and Harshness (NVH) development tools which are fast, precise and, seamlessly interchangeable between development sites, suppliers and OEMs. Component-based Transfer Path Analysis (C-TPA), standardized in ISO 20270:2019, enables independent component characterization and integration with virtual models to predict sound and vibration in new assemblies, referred to as Virtual Prototype Assemblies (VPA). However, conventional measurements are labor-intensive, typically restricted to a small number of samples, and overlook production variability. This paper introduces a fully automated, ISO 20270-compliant C-TPA system for non-rigid test benches, featuring a pre-instrumented test fixture with multiple vibration shakers and sensors automatically linked to a data acquisition system for immediate processing. Components can be characterized within minutes, with blocked forces directly integrated into a VPA workflow, replacing time-intensive in-vehicle testing with a repeatable, operator-independent bench procedure. A case study on an automotive steering system demonstrates the method’s accuracy, repeatability, and efficiency, along with its ability to predict realistic interior sound pressure levels and capture production variability, enabling robust virtual NVH evaluation early in the development cycle.
AMS6885/1 gives information about the technical requirements and qualification procedure for unidirectional carbon fiber tape epoxy repair prepreg capable of curing under vacuum for repair of carbon fiber reinforced epoxy structures. The repair system includes an epoxy film adhesive to be applied in a co-bonding process with the prepreg for solid laminate and sandwich bonding.
The increasing pressure to decarbonize manufacturing systems is pushing industry beyond conventional lightweighting strategies toward material and process paradigms, capable of delivering functional performance with radically lower environmental impact. In this context, polymer-based composite Additive Manufacturing (AM) offers an underexplored yet highly promising pathway for sustainable production of load-bearing components. This study presents a preliminary comparative cradle-to-gate Life Cycle Assessment (LCA) of a Formula SAE brake pedal, assessing the environmental transition from conventional sheet metal fabrication and finishing operations of Aluminum 7075-T6 to additive manufacturing solutions, with specific focus on Carbon-Fiber-Reinforced Polymer (CFRP) composites. Two topology-optimized designs, respectively for Powder Bed Fusion (PBF) in AlSi10Mg and Material Extrusion (MEX) in Polyethylene Terephthalate Glycol with Carbon Fiber (PETG-CF) are compared to conventional fabrication aluminum benchmark. The analysis is integrated in the product and process design following ISO 14040/14044 standards and is implemented using the Environmental Footprint 3.0 methodology within the 3DEXPERIENCE platform. Results outline that Material Extrusion (MEX) composite manufacturing achieves the lowest environmental impact across all evaluated categories. Compared to conventional manufacturing, the PETG-CF solution enables an approximate 50% reduction in Global Warming Potential and an almost complete elimination of mineral depletion. Unlike metal additive manufacturing, which remains constrained by high process energy demand, MEX benefits from low processing temperatures, minimal auxiliary systems, and highly efficient material deposition. Crucially, these sustainability gains are achieved while maintaining functional performance through design-driven topology optimization. AM composite solutions, by merging advanced material science with additive flexibility, may lead to design approaches which cease to be ‘potential’ enablers of sustainable manufacturing for the Industry 5.0 transition.
This digital standard is a requirements extract of AS13100A Quality Management System Requirements for Aero Engine Design and Production Organizations. This file contains a general requirements extraction as well as files that are optimized for use with Doors Classic, Siemens Polarian, and PTC.
Precision agriculture, also known as smart farming, was once reserved for early adopters or large-scale operations, but is now an expectation within the farming industry. Across various regions and farm sizes, smart farming techniques are changing the way crops are planted as well as how they are monitored and harvested. However, farmers today are under increasing pressure to reduce labor, decrease chemical inputs, conserve water and operate in tighter windows. Couple this with factors such as narrow seasonal windows, productivity demands and safety considerations, and the need for smarter decisions becomes imperative. Going one step further, global food demands and environmental pressures are further increasing demand for precise, accurate and intelligent farming solutions.
Moog Inc. introduced its new adaptive electrification management system (AEMS) at a press conference during CONEXPO 2026 in Las Vegas. Moog states that this system offers a path to electrify, automate and digitalize construction machinery more efficiently and cost-effectively. “End users in the off-highway market are demanding that their machines have higher productivity and a lower total cost of ownership,” said Dr. Nate Keller, Moog strategic business manager. “OEMs are working to solve this problem, and one of the particular ways is through electrification.”
Space vehicle and satellite development programs are driving demand for new small- and medium-sized satellites across commercial and defense imaging, data collection, and other space-based applications.
This SAE standard establishes the requirement for suppliers to plan a reliability program that satisfies the following three requirements: a The supplier shall ascertain customer requirements b The supplier shall meet customer requirements c The supplier shall assure that customer requirements have been met
This paper presents the implementation of a fully automated Health and Usage Monitoring System (HUMS) data chain designed to accelerate installed engine performance diagnostics during the pre-delivery phase of new-generation helicopters. Ensuring that engine performance remains consistent with original engine manufacturer (OEM) baseline data is a critical step in the final assembly process, yet traditionally time-consuming. The developed system automates data offloading and integrates three distinct streams: OEM engine performance characteristics, in-flight Engine Power Checks (EPC), and high-frequency continuous recordings. The core innovation lies in a multi-source data fusion methodology combined with a physics-based model to differentiate between genuine installation discrepancies and sensor anomalies through temperature deviation analysis. Results from the production environment demonstrate that this automated approach significantly reduces troubleshooting lead times and ensures on-time aircraft delivery. By shifting advanced monitoring from in-service operations to manufacturing, this system establishes a new digital benchmark for quality control in helicopter production.
This will be my last column for SAE Automotive Engineering after an 11-year run. Don't worry, I'm not going anywhere, just taking a monthly column off my plate to enable more time to spend with my grandson and focus on other passions. While I have been a forecaster for nearly four decades, writing a column for an external publication was always an important outlet for ideas. An opportunity to outline a trend, event, or development that would change the fortunes of our industry, specifically for suppliers. While OEMs get the headlines and the accolades, supporting the unsung supply base has been Job 1 in my book.
Despite reports saying the company could delay production until 2028 due to technical challenges, the CEO of Scout Motors, the made-in-America electric SUV and truck startup, said the plan is still to have prototype cars come “down the line” in 2027 with customer vehicles following “thereafter.” Scott Keogh said life as a startup company producing electric vehicles from a clean sheet is a life of on-the-fly adjustments. “There are technical challenges every minute of every day,” he said at an Automotive Press Association briefing at the company's Novi, Michigan tech and engineering site. “But there are no defining ‘oh my god’ technical challenges that can't be solved.”
Leonardo DRS has opened a new naval power and propulsion manufacturing and testing facility in Charleston, South Carolina, expanding its role in delivering next generation electric propulsion, integrated power systems, and high energy payload support for U.S. Navy surface and undersea platforms. The 140,000 square foot site consolidates advanced manufacturing, final assembly, and high fidelity testing for electric power conversion and propulsion systems, while also supporting naval steam turbine design, production, and subsystem integration for programs including the Columbia class ballistic missile submarine. A representative for Leonardo's Naval Power Systems business unit provided emailed statements with details about the type of advanced manufacturing the company will deploy at the new facility.
The advanced construction equipment packing the convention center halls and surrounding lots will understandably be the stars of the triennial CONEXPO trade show, taking place March 3-7 in Las Vegas. But the latest technologies in fluid power and motion control that help those machines operate efficiently will also command attention from showgoers. The Bosch Rexroth mobile hydraulics team will be on-site in a joint booth with partner HydraForce (Booth S80245), showcasing their current product portfolio. Rafael Cardoso, Bosch Rexroth engineering manager, mobile systems and software, expects to have conversations about advanced control and automation, “focused on the demand for smarter, software-driven control strategies that enhance precision, productivity, downtime reduction and operator assistance features.”
Green hydrogen, produced through water electrolysis, is a next-generation eco-friendly energy source as it does not generate pollutants like carbon dioxide during production. Catalysts play a crucial role in the water electrolysis process, splitting water into hydrogen and oxygen. The efficiency of green hydrogen production largely depends on the performance of these catalysts. Therefore, the commercialization of green hydrogen hinges on the development of cost-effective catalysts capable of maintaining high performance over extended periods.
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