Browse Topic: Quality control
Wire Electrical Discharge Machining (WEDM) is an important method engaged to make intricate shapes in conductive materials like Cupronickel, which is well-known for its ability to resist corrosion and conduct heat. The intention of this exploration is to enhance the effectiveness and accuracy of Wire Electrical Discharge Machining (WEDM) for Cupronickel material by utilizing a Taguchi-based Grey Relational Analysis (GRA). The study examines the impact of WEDM parameters, specifically pulse-on time, pulse-off time, and discharge current, on key machining outcomes such as surface roughness (Ra), material removal rate (MRR). A comprehensive dataset is generated for analysis through a systematic series of experiments designed using the Taguchi method. Grey relational grades are assessed to measure the connections between the input parameters and machining responses, making it easier to determine the best parameter settings. The Taguchi-based GRA approach provides a systematic approach for
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
ABSTRACT The key to a better correlation between the interface of systems engineering and project management is in fact a strong sigma relationship. In the recent past this would be termed Value Engineering and was that activity that took place prior to cutting the tools, but it is considerably more common today with the computer systems and software suites in use for modeling and the emphasis on Design for Six Sigma and time to market. All of these tools and methodologies are placing the focus on the final product performance, quality and cost and in so doing helping to again strengthen the manufacturing posture and job outlook of America and re-shore much of the work that was outsourced to save money. Whether of Military or U.S. vehicle manufacturing requirements, for the safety of our programs this work can and should stay in the United States when appropriate. This paper will develop better tools solutions, to provide better risk decisions which improve safety, budget, predictions
ABSTRACT Of the tests of any good theory or suppositional work, the most critical is whether it can forecast the need or accurately describe the number, timing, event and impact of the endeavor. In order to reduce the risk and to exponentially increase the rate of success a continual reevaluation of the data and reconfiguration of the plan will be required, must be properly front-loaded with the appropriate human capital. This is precisely where the application of Six Sigma, Project Management and, Six Sigma for Human Capital works’ intimately with Risk Management to mitigate error and insure the ultimate success of the effort. This is critical in business, critical in the field for greater energy efficiency for soldiers. Unified in concert as core disciplines, the identification of human capital for specialists required at any particular point in the project especially in the definition and design phases, is determined with greater accuracy. Critically predictable and integrated into
ABSTRACT Leveraging an open standard may still not achieve the desired interoperability between systems. Addressing “lessons learned” from past implementations of open standards for various Department of Defense (DoD) acquisition programs is critical for future success. This paper discusses past issues which range from insufficient technical detail, when and how to apply a given specification, verification of an implementation’s compliance, to inconsistent and imprecise contractual language. This paper illustrates how the Vehicular Integration for C4ISR/EW Interoperability (VICTORY) initiative addresses these challenges to enable interoperability on Army ground vehicles, as well as facilitate rapid technology insertion and incorporation of new capabilities. VICTORY represents a leap ahead in solving interoperability challenges and defining open standards
ABSTRACT The Integrated Systems Engineering Framework (ISEF) is an Army Research, Development, and Engineering Command (RDECOM) solution to address stovepiped systems engineering(SE) information and processes, disparate tools united by custom, one-off integrations, and a lack of accepted, common standards that exists in today’s Department of Defense (DoD) operating environment. Ever increasing technical complexity of fielded solutions combined with budgetary constraints push DoD engineers to “do more with less,” requiring a technical management solution that allows them collaborate virtually yet effectively with distributed engineers and other stakeholders. Easy access to systems engineering tools and information through a single “cloud” based application allows connections between federated databases, and facilitates knowledge preservation over time to avoid “reinventing the wheel” when new programs replace retired ones. ISEF is an ever-expanding collection of systems engineering
ABSTRACT Reliability Physics simulations for electronic assemblies has matured to become best practice during specification and design. However, the potential advantages of these simulations to programs and integrators are more far reaching. This paper will explore how the simulations can be used for virtual qualification, reliability assurance, maintenance scheduling and obsolescence management. Citation: Ed Dodd, “Reliability Simulations for Electronic Assemblies: Virtual Qualification, Reliability Assurance, Maintenance Scheduling and Obsolescence Mitigation”, In Proceedings of the Ground Vehicle Systems Engineering and Technology Symposium (GVSETS), NDIA, Novi, MI, Aug. 13-15, 2019
ABSTRACT Silicon carbide (SiC) semiconductor devices offer several advantages to power converter design when compared with silicon (Si). An increase in power density can be achieved with SiC thanks to the reduced conduction and switching losses and to the ability to withstand higher temperatures [1]. The main system level benefits of using SiC devices on mobile hybrid power systems include large reductions in the size, weight, and cooling of the power conditioning. In this paper, the authors describe the Wide-bandgap-enabled Advanced Versatile Energy System (WAVES) with a focus on the design and testing of a SiC prototype of a WAVES power inverter. The prototype is a 10 kW three-phase AC/DC inverter that is air-cooled, IP-67 rated, bi-directional, operates down to a power factor of 0.4, and designed to have overload capability up to 350% for up to 250µs of nominal rating. Because the inverter is bidirectional, it may be used as an AC input to DC output battery charger or as a DC input
In recent years, battery electric vehicles (BEVs) have experienced significant sales growth, marked by advancements in features and market delivery. This evolution intersects with innovative software-defined vehicles, which have transformed automotive supply chains, introducing new BEV brands from both emerging and mature markets. The critical role of software in software-defined battery electric vehicles (SD-BEVs) is pivotal for enhancing user experience and ensuring adherence to rigorous safety, performance, and quality standards. Effective governance and management are crucial, as failures can mar corporate reputations and jeopardize safety-critical systems like advanced driver assistance systems. Product Governance and Management for Software-defined Battery Electric Vehicles addresses the complexities of SD-BEV product governance and management to facilitate safer vehicle deployments. By exploring these challenges, it aims to enhance internal processes and foster cross
An industry-first 3D laser-based, computer-vision system can monitor and control the application of adhesive beads as tiny in width as two human hairs. This unique inspection system for electronic assemblies operates at speeds of 400 to 1,000 times per second, considerably quicker and more effective than conventional 2D systems. “Difficulty in precisely dispensing adhesives or sealants, especially in extremely small or complex electronic assemblies, can lead to over-application, under-application, bubbles, or incorrect location of the adhesive bead,” Juergen Dennig, president of Ann Arbor, Michigan-headquartered Coherix, told SAE Media. Improper application of joining material on electronic control units (ECUs) and power control units (PCUs) can result in poor adhesion, material voids and short circuits
Vehicle HVAC noise performance is an important vehicle design validation criterion since it significantly links the brand image of a vehicle. It affects the customer’s buying decision and the business of selling vehicles because it directly affects driving comfort. Customers expect continuous improvement in HVAC noise without compromising cooling performance. The process of cascading vehicle-level acoustic performance to subsystem and component levels becomes an important factor in the vehicle NVH development process. It was found that the component-level [HVAC unit without duct] performance of an HVAC system measured in an anechoic chamber was at par when compared to targets, whereas the subsystem-level performance [HVAC unit with duct and dashboard] was on the higher side of the targets. Advanced NVH tools were used to identify the source of noise at the subsystem level. It helped to locate the source and its transfer path. A design modification done at the transfer path location
To provide a method by which to assess the cleanliness of new hydraulic fluids. The method is applicable to new mineral and synthetic hydraulic fluids - regardless of packaging. This SAE Standard is not intended as a procedure for operating equipment
This SAE Aerospace Recommended Practice (ARP) covers the requirements for the types of glass to be utilized in the fabrication of cover glasses and lighting wedges used in aerospace instruments. It defines the maximum extent of physical defects and recommends standard methods of inspection and evaluation. Definitions of terminology used in this document are covered in 2.2
A company says that its digital twin alignment system, incorporating a sophisticated AI algorithm and an off-the-shelf camera, has the potential to revolutionize the auto industry, potentially saving it up to a staggering $20 billion in the effort to detect defects on the manufacturing line. Generally, such inspections of spot welds, bolt holes and the like are handled one of three ways: Slow manual inspections that can have high error rates. Even slower inspection with coordinate-measuring machines (CMMs) that can take hours to inspect 150 spot welds. Tremendously expensive technology, such as lasers, that still aren't perfect
Design verification and quality control of automotive components require the analysis of the source location of ultra-short sound events, for instance the engaging event of an electromechanical clutch or the clicking noise of the aluminium frame of a passenger car seat under vibration. State-of-the-art acoustic cameras allow for a frame rate of about 100 acoustic images per second. Considering that most of the sound events introduced above can be far less than 10ms, an acoustic image generated at this rate resembles an hard-to-interpret overlay of multiple sources on the structure under test along with reflections from the surrounding test environment. This contribution introduces a novel method for visualizing impulse-like sound emissions from automotive components at 10x the frame rate of traditional acoustic cameras. A time resolution of less than 1ms eventually allows for the true localization of the initial and subsequent sound events as well as a clear separation of direct from
A sensing technology that can assess the quality of components in fields such as aerospace could transform UK industry. University of Bristol, Bristol, UK In a study, published in the Journal Waves in Random and Complex Media, researchers from the University of Bristol have derived a formula that can inform the design boundaries for a given component's geometry and material microstructure. A commercially viable sensing technology and associated imaging algorithm to assess the quality of such components currently does not exist. If the additive manufacturing (3D printing) of metallic components could satisfy the safety and quality standards in industries there could be significant commercial advantages in the manufacturing sector
In a study, published in the Journal Waves in Random and Complex Media, researchers from the University of Bristol have derived a formula that can inform the design boundaries for a given component’s geometry and material microstructure
The aviation, space, and defense industries rely on the development and manufacture of complex products comprised of multiple systems, subsystems, and components each designed by individual designers (design activities) at various levels within the supply chain. Each design or manufacturing activity controls various aspects of the configuration and specifications related to the product. When a change to design or process is requested or required, the change is typically required to be evaluated against the impacts to the entire system. Proposed changes to design data/information that the design activity identifies to be minor and have no effect on the product requirements or specifications, have the potential to be implemented and approved, where authorized to do so, but requires notification. Changes that affect customer mandated requirements or specifications shall be approved prior to implementation. In many cases, the design activity is not conducted by the DAH or design authority
In this paper, in order to obtain the specified communication range, this work provides a novel optimization approach for antenna placement inside a design space of a vehicle is proposed. The design community can undertake antenna design iterations and quickly investigate antenna placement areas with the help of the optimal placement of antenna utilizing computational electromagnetic (CEM) based optimization approach. The design of experiments (DOE) for various antenna positions and orientations was produced using the Taguchi method [5]. To examine the impact of near field E throughout communication range, Quasi-Newtonian gradient technique and high frequency simulation software (HFSS) are employed. Response curves were created from the received near field E in order to examine the mean, large mean, and cost-wise approaches in order to find the antenna's ideal position and orientation for a strong signal across the communication range
The Auto industry has relied upon traditional testing methodologies for product development and Quality testing since its inception. As technology changed, it brought a shift in customer demand for better vehicles with the highest quality standards. With the advent of EVs, OEMs are looking to reduce the going-to-market time for their products to win the EV race. Traditional testing methodologies have relied upon data received from various stakeholders and based on the same tests are planned. The data used is highly subjective and lacks variety. OEMs across the world are betting big on telematics solutions by pushing more and more vehicles with telematics devices as standard fitment. The data from such vehicles which gets generated in high levels of volume, variety and velocity can aid in the new age of vehicle testing. This live data cannot be simply simulated in test environments. The device generates hundreds of signals, frequently in a fraction of seconds. Multiple such signals can
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