Browse Topic: Production
The automotive industry is facing unprecedented pressure to reduce costs without compromising on quality and performance, particularly in the design and manufacturing. This paper provides a technical review of the multifaceted challenges involved in achieving cost efficiency while maintaining financial viability, functional integrity, and market competitiveness. Financial viability stands as a primary obstacle in cost reduction projects. The demand for innovative products needs to be balanced with the need for affordable materials while maintaining structural integrity. Suppliers’ cost structures, raw material fluctuations, and production volumes must be considered on the way to obtain optimal costs. Functional aspects lead to another layer of complexity, once changes in design or materials should not compromise safety, durability, or performance. Rigorous testing and simulation tools are indispensable to validate changes in the manufacturing process. Marketing considerations are also
The goal of this work is to increase the accuracy and efficiency of hose cutting operations in small scale industries is by designing and building an automatic hose-cutting equipment. The device uses a computer-controlled system to autonomously cut pipes of various sizes and lengths. By means of a stepper motor-driven, rapidly spinning blade, the cutting process is accomplished. Additionally, the machine has sensors that measure the hose's length and modify the cutting position as necessary. Premium components and materials are used in the machine's construction; these are chosen for their performance and longevity. The device is able to boost cut precision and raise industry production all around from 100% to 190% efficient system thereby decreasing labor and time needed for hose cutting operations
Wire Electrical Discharge Machining (WEDM) is a widely used manufacturing method that is employed to shape complex geometries in conductive materials such as cupronickel, which is highly regarded for its resistance to corrosion and ability to conduct heat. The aspiration of this investigation is to improve the effectiveness and accuracy of Wire Electrical Discharge Machining (WEDM) for cupronickel material by utilizing the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) optimization method. The study analyzes the impact of WEDM parameters, specifically pulse-on time, pulse-off time, and discharge current, on important machining outcomes such as surface roughness, material removal rate. Experimental trials are performed to collect data on these parameters and their corresponding machining characteristics. The TOPSIS optimization method is utilized to determine the most favourable parameter settings by evaluating each parameter combination against the ideal and
Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), has transformed the manufacturing industry by allowing the creation of intricate shapes using different materials. Polylactic Acid (PLA) is a biodegradable thermoplastic that is commonly used in additive manufacturing (AM) because of its environmentally friendly nature, affordability, and ease of processing. This study aims to optimize the parameters of Fused Deposition Modeling (FDM) for PLA material using the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) approach. The researchers performed experimental trials to examine the impact of important FDM parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on critical outcomes, including dimensional accuracy, surface finish, and mechanical properties. The methodology of design of experiments (DOE) enabled a systematic exploration of parameters. The TOPSIS approach, a technique for making decisions
Additive Manufacturing (AM), specifically Fused Deposition Modeling (FDM), has become a highly promising method for creating intricate shapes using different materials. Polyethylene Terephthalate Glycol (PETG) is a highly utilized thermoplastic that is recognized for its exceptional strength, resistance to chemicals, and effortless processing. This study aims to optimize the process parameters of the FDM technique for PETG material using Taguchi Grey Relational Analysis (GRA). An empirical study was carried out to examine the impact of various FDM process parameters, such as layer thickness, infill density, printing speed, and nozzle temperature, on important outcome variables like dimensional accuracy, surface quality, and mechanical properties. The Taguchi method was used to systematically design a series of experiments, while GRA was used to optimize the process parameters and performance characteristics. The results unveiled the most effective parameter combinations for attaining
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
Additive Manufacturing (AM), specifically Fusion Deposition Modeling (FDM), has transformed the manufacturing industry by allowing the creation of complex structures using a wide range of materials. The objective of this study is to enhance the FDM process for Thermoplastic Polyurethane (TPU) material by utilizing the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) optimization method. The study examines the influence of FDM parameters, such as layer height, nozzle temperature, and infill density, on important characteristics of the printing process, such as tensile strength, flexibility, and surface finish. The collection of experimental data is achieved by conducting systematic FDM printing trials that cover a variety of parameter combinations. The TOPSIS optimization method is utilized to determine the optimal parameter settings by evaluating each parameter combination against the ideal and anti-ideal solutions. This method determines the optimal parameter
There is great recognition regarding the importance of hydrogen as an energy route for the decarbonization of road vehicles. Several countries are making large investments to create products, services, and infrastructures that allow hydrogen to be used as a clean source for propulsion, but there are still many open questions. This complete hydrogen chain involves production, transformation, transport, storage, and use. Although many initiatives are seeking global production, the use of low-carbon hydrogen is not yet economically competitive. Therefore, for this industry to establish itself, and acknowledging the characteristics of each region, there needs to be more intense coordination of efforts between the different industrial and political segments. Low-carbon Hydrogen Use Across Economic Sectors and Global Regions establishes premises for the hydrogen economy and its main environmental aspects. It also includes proposals and scenarios to establish a strategy that relates to
Summary This paper discusses the latest techniques in vehicle modeling and simulation to support ground vehicle performance and fuel economy studies, enable system design optimization, and facilitate detailed control system design. The Autonomie software package, developed at Argonne National Laboratory, is described with emphasis on its capabilities to support Model-in-the-Loop, Software-in-the-Loop (SIL), Component-in-the-Loop (CIL), and Hardware-in-the-Loop simulations. Autonomie supports Model-Based Systems Engineering, which is growing in use as ground vehicles become more sophisticated and complex, with many more subsystems interacting within the vehicle and the environmental conditions in which the vehicles operate becoming more challenging and varied. With the advent of hybrid powertrains, the additional dimension of vehicle architecture has become one of the design variables that must be considered. This complexity results in the need for a simulation tool that is capable of
ABSTRACT The Bradley Combat Vehicle Motor Chatter case study focuses on one aspect of a combat vehicle program, specifically, responding to a vehicle production situation where combat vehicles produced with in-spec components and subsystems exhibit out-of-spec and failing system behavior. This typically results in an extended production line-down or line-degraded situation lasting for several quarters until the problem can be diagnosed, fixed, validated and verified. Subsequently, adequate quantities of the modified or replaced sub-systems must be put back into the production flow. The direct and indirect costs of an occurrence like this in peace-time are measured in the 10’s to 100’s of Millions of dollars. The schedule, program and perception impact to the vehicle platform can be potentially devastating. In war-time all of these impacts are magnified greatly by the added risk to soldiers’ lives. This paper describes the Bradley Combat Vehicle Motor Chatter case study and the
Abstract Converting vehicles from conventional manned operations to unmanned supervised operations has been slow to adoption in many industries due to cost, complexity (requiring more highly skilled personnel) and perceived lower productivity. Indeed, hazardous operations (military, nuclear cleanup, etc.) have seen the most significant implementations of robotics based solely on personnel safety. Starting in 2005, the U.S. Army Corps of Engineers (USACE) has assumed a leading role in promoting the use of robotics in unexploded ordnance (UXO) range remediation. Although personnel safety is the primary component of the USACE mission, increasing productivity while reducing overall cost is an extremely important driver behind their program. To achieve this goal demands that robotic range clearance equipment be affordable, easy to install on rental equipment, durable and reliable (to minimize down-time), low or no maintenance, and easy to learn / operate by the same individuals who would
ABSTRACT The key to vehicle survivability in a combat or otherwise hostile environment is the capability to quickly resupply critical parts. Rapid production of hard to obtain components within the theater of operations can significantly increase the availability of combat vehicles or other equipment. Additive manufacturing enables significant reduction in lead time for these components and thus offers an enhancement of combat capability. However, AM operations have specific environmental and support requirements in order to function. In partnership with CESI and CAPSA, AddUp has developed a unique concept of a “modular plant” called the Anywhere Additive Factory. The unit can be adjusted to meet the manufacturing requirements and volumes needed, while also being easily dismantled and moved to another location. Citation: S. Pexton, “The FlexCare Deployable Additive Manufacturing Printing Facility”, In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium
ABSTRACT The United States Army is leveraging Advanced Manufacturing (AdvM) methods to solve both operational and tactical readiness gaps. AdvM includes not only Additive Manufacturing (AM), but also traditional manufacturing capabilities in the field and at Army production facilities. The Tank-Armaments and automotive Command (TACOM) and the Ground Vehicles Systems Center (GVSC) Materials-AdvM Branch have developed a strategy of five critical path key words oriented on three Lines of Effort (LOE) that enables a disciplined process to deliver final use qualified parts manufactured by the Organic Industrial Base (OIB) as an alternate source of supply that will improve readiness of TACOM’s combat and tactical wheeled fleets. Additionally, an alternate critical path has been developed to provide limited use parts for Battle Damage and Repair (BDAR). Citation: P. Burton, N. Kott, A. Kruz, A. Batjer, “Path to 450 Parts Qualified for Advanced Manufacturing”, In Proceedings of the Ground
ABSTRACT The Digital Engineering Environment is new and rapidly changing. It is a complex system with many tools, databases and views. Organizations struggle with how to access their maturity in a new environment. This paper discusses the different aspects of determination of the maturity of architecture model within a Digital Engineering Environment. The intended audience is all levels of system engineers. It will address the characteristics of maturity from content, size and usefulness of architecture models. The goal of this paper is to provide system architecture with tools, process and insight into gaining more productivity and value from architecture models
Abstract On the Mobile Detection Assessment Response System (MDARS) production program, General Dynamics Robotics Systems (GDRS) and International Logistics Systems (ILS), are working with the US Army’s Product Manager – Force Protection Systems (PM-FPS) to reduce system costs throughout the production lifecycle. Under this process, GDRS works through an Engineering Change Proposal (ECP) process to improve the reliability and maintainability of subsystem designs with the goal of making the entire system more producible at a lower cost. In addition, GDRS recommends substitutions of Government requirements that are cost drivers with those that reduce cost impact but do not result in reduced capability for the end user. This paper describes the production lifecycle process for the MDARS system and recommends future considerations for fielding of complex autonomous robotic systems
ABSTRACT This paper focuses on the application of a novel Additive Molding™ process in the design optimization of a combat vehicle driver’s seat structure. Additive Molding™ is a novel manufacturing process that combines three-dimensional design flexibility of additive manufacturing with a high-volume production rate compression molding process. By combining the lightweighting benefits of topology optimization with the high strength and stiffness of tailored continuous carbon fiber reinforcements, the result is an optimized structure that is lighter than both topology-optimized metal additive manufacturing and traditional composites manufacturing. In this work, a combat vehicle driver’s seatback structure was optimized to evaluate the weight savings when converting the design from a baseline aluminum seat structure to a carbon fiber / polycarbonate structure. The design was optimized to account for mobility loads and a 95-percentile male soldier, and the result was a reduction in
This specification covers metric aircraft quality spacers for use as positioners for tubes, flat washers for use as load spreaders, galling protection of adjacent surfaces and or material compatibility, and key or tab washers for use as locks for bolts, nuts, and screws
Contrary to what you may have heard, Americans are buying more EVs than ever. But they tend to like 'em big. After production delays due to software development issues - a problem that continues to plague automakers from Volkswagen to General Motors - Volvo's EX90 will look to lure families who live for three-row luxury SUVs. Based on a recent media drive in Newport Beach, California, Volvo may still have some work to do. The twin-motor EX90 did impress us with its 510 hp (380 kW), confident handling, leading-edge safety and sparkling high-resolution displays. But a software glitch dinged our test car when a section of its 14.5-inch (37 cm) center screen blanked out. Other journalists reported issues with a phone-based digital key that briefly left one driver stranded when it wouldn't connect with the Volvo. This is another reason I never rely on an automaker's digital key and always ask for a hard backup
Mi Rancho has been delighting customers with authentic and fresh tortillas, chips, and salsas since its establishment in 1939. Originally founded as a grocery store in Oakland, CA, the business has evolved and grown into a food provider for large nation-wide retail partners. To enable their continued growth, Mi Rancho recently partnered with Formic to introduce robotic automation to their food processing and packaging production operations
High productivity, low manufacturing costs, and high workpiece quality: these are the key factors that deliver sustainability, profitability, and competitive edge for industrial manufacturers. Reliable machine monitoring yields valuable real-time insights into ongoing processes; it is the basis for dependable, productive, and reproducible manufacturing and it helps machine operators to reach well-founded decisions on both short- and long-term improvements. This technology can even capture anomalies in highly dynamic machining processes, so users can respond instantly to ensure high productivity, decrease scrap rates, and prolong tool lifetimes. Thanks to all these advantages, continuous machine and process monitoring based on suitable sensor technology is a critical success factor in today’s manufacturing industry
The impact of the upcoming U.S. federal election, global trade turmoil, a mediocre U.S. economy and the slumping ICE-to-EV (internal combustion engine to electric vehicle) transition must be considered. In my last column, we explored the growing use of scenarios to provide guardrails for future strategy. Suppliers can no longer rely upon a single forecast to drive future planning. The main culprits clouding the planning environment are program delays, rescopes and EV strategy shifts accompanied by the extension of ICE/hybrid models. The trajectory of EV launches and new offerings is decidedly ahead of the skis of consumer acceptance. This supply-and-demand mismatch is an ongoing challenge. It is important to understand the severity of program changes amid this slowing EV growth environment
This standard establishes requirements for Process Control Methods to sustain product conformity. This includes training, selection of control methods, analysis and improvement of their effectiveness, and subsequent monitoring and control. It applies to all controls documented in the Control Plan. This will include but is not limited to Key Characteristics (KCs) and Critical Items (CIs). This standard aligns and collaborates with the requirements of AS9100, AS9103, AS9145, AS13000, AS13002, AS13003, and AS13004. Commercial-Off-The-Shelf (COTS) items and Standard Catalogue Items (that neither the customer nor supplier hold design authority for) are not included
The Software Production Factory (SPF) is a cyber physical construct of computers, hardware and software integrated together to serve as an ideation and rapid prototyping environment. SPF is a virtual dynamic environment to analyze requirements, architecture, and design, assess trade-offs, test Ground Vehicle development artifacts such as structural and behavioral features, and deploy system artifacts and operational qualifications. SPF is utilized during the product development as well as during system operations and support. The white paper describes the components of the SPF to build relevant Ground Vehicle Rapid Prototyping (GVRP) models in accordance with the model-centric digital engineering process guidelines. The factory and the processes together ensure that the artifacts are produced as specified. The processes are centered around building, maintaining, and tracing single source of information from source all the way to final atomic element of the built system
This document provides guidance for oxygen cylinder installation on commerical aircraft based on airworthiness requirements, and methods practiced within aerospace industry. It covers considerations for oxygen systems from beginning of project phase up to production, maintenance, and servicing. The document is related to requirements of DOT-approved oxygen cylinders, as well to those designed and manufactured to standards of ISO 11119. However, its basic rules may also be applicable to new development pertaining to use of such equipment in an oxygen environment. For information regarding oxygen cylinders itself, also refer to AIR825/12
Today, advancements in industrial laser cleaning automation show great promise in boosting productivity and safety when rust and contaminant removal or surface preparation is required for higher volumes of components and equipment
In the medical device production environment, device packaging and sterilization is vital. The same level of rigorous quality controls and regulations that affect the devices themselves are also extended to their packaging. The mechanical and container closure integrity [CCI] evaluations of medical device packaging requires significant testing performed at multiple points throughout the commercialization and production processes
This SAE Aerospace Standard (AS) establishes requirements applicable to metal stock that is ordered and produced in accordance with an SAE Aerospace Material Specification (AMS). Topics include producer requirements, distributor requirements, size and grain orientation nomenclature, and purchaser ordering information to distributors. Requirements of this document have been developed to address titanium and titanium alloys, aluminum and aluminum alloys, carbon and alloy steels, and corrosion- and heat-resistant alloys
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