Assembly Automation

Purpose -The aim of the research was to evaluate the concept that utilizes structured planar substrates based on low temperature co-fired ceramics (LTCC) as a precision platform for the passive alignment of a multimode fiber and wide-stripe diode laser. Design/methodology/approach -Presents the manufacturing process for realisation of 3D precision structures, heat dissipation structures and a cooling channel into the LTCC substrate. The developed methodology for 3D modelling and simulation of the system was used to optimize structures, materials and components in order to achieve optimal performance for the final product and still maintain reasonably low fabrication costs. The simulated optical coupling efficiency and alignment tolerances were verified by prototype realization and characterization. Findings -The achieved passive alignment accuracy allows high coupling efficiency realisations of multimode fiber pigtailed laser modules and is suitable for mass production. Research limitations/implications -Provides guidance in the design of LTCC precision platforms for passive alignment and presents a hybrid simulation method for photonics module concept analysis. Practical implications -The three-dimensional shape of the laminated and fired ceramic substrate provides the necessary alignment structures including holes, grooves and cavities for the laser to fiber coupling. Thick-film printing and via punching can be incorporated in order to integrate electronic assemblies directly into the opto-mechanical platform. Originality/value -Introduces the LTCC 3D precision structures for photonics modules enabling passive alignment of multimode fiber pigtailed laser with high efficiency optical coupling. Demonstrates the hybrid simulation methodology for concept analysis.

Purpose -The aim of the research was to evaluate the concept that utilizes structured planar substrates based on low temperature co-fired ceramics (LTCC) as a precision platform for the passive alignment of a multimode fiber and wide-stripe diode laser. Design/methodology/approach -Presents the manufacturing process for realisation of 3D precision structures, heat dissipation structures and a cooling channel into the LTCC substrate. The developed methodology for 3D modelling and simulation of the system was used to optimize structures, materials and components in order to achieve optimal performance for the final product and still maintain reasonably low fabrication costs. The simulated optical coupling efficiency and alignment tolerances were verified by prototype realization and characterization. Findings -The achieved passive alignment accuracy allows high coupling efficiency realisations of multimode fiber pigtailed laser modules and is suitable for mass production. Research limitations/implications -Provides guidance in the design of LTCC precision platforms for passive alignment and presents a hybrid simulation method for photonics module concept analysis. Practical implications -The three-dimensional shape of the laminated and fired ceramic substrate provides the necessary alignment structures including holes, grooves and cavities for the laser to fiber coupling. Thick-film printing and via punching can be incorporated in order to integrate electronic assemblies directly into the opto-mechanical platform. Originality/value -Introduces the LTCC 3D precision structures for photonics modules enabling passive alignment of multimode fiber pigtailed laser with high efficiency optical coupling. Demonstrates the hybrid simulation methodology for concept analysis.

Purpose – Laser milling is a recent process in mould making, providing several advantages over traditional mould making technologies by reducing manufacturing time, shortening the number of machining operations and avoiding expensive electrodes. This paper investigates the ...

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Purpose -This paper seeks to analyse the internal materials flow in lean manufacturing in an assembly line of the Bosch factory, located in Spain. The objective is to develop a handling system in a small space, capable of solving the problems of accumulated intermediate stocks of parts. An improvement is proposed adopting the milkrun handling system, while verifying the advances by means of lean metrics. Design/methodology/approach -Based on this case study, the paper identifies data from value stream mapping and uses lean metrics, such as dock-to-dock time and lean rate. The case study develops a timetable and routing analysis for the milkrun to improve materials flow. Findings -The proposed logistics allows an improvement of lean metrics, without modifying the layout and production planning. The routing flexibility of the milkrun reduced stocks, work-in-process and dock-to-dock time, while increasing lean rate.

The paper gives a brief overview of the creativity supporting methods of potential interest to process engineering community. Information about computer implementations of the presented methods is introduced as well. Creative problem solving can be broadly classified into intuitive and analytical methods-the paper suggests the analytical approaches to creative problem solving as the most promising group for process engineers. Special attention is given to TRIZ, a popular method for systematic creativity. Classical TRIZ needs to be modified in order to be used in a specialised domain such as process engineering. We discuss the changes needed and illustrate the application of the modified TRIZ to the design of inherently safer chemical processes. A discussion of the advantages and drawback of creativity enhancing methods in the context of process engineering is also presented along with directions for future development.

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The use of Additive Manufacture (AM) in New Product Development (NPD) has increased over recent years. AM enables greater creativity in design, reduced tooling cost and faster product development time. However, there is a lack of available information to empower designers to take full advantage of AM. It is anticipated that the database will serve as a rich source of inspirational information for design practitioners and students.

Current major roadmapping efforts have all clearly underlined that true industrial sustainability will require far higher levels of systems' autonomy and adaptability. In accordance with these recommendations, the Evolvable Production Systems (EPS) has aimed at developing such technological solutions and support mechanisms. Since its inception in 2002 as a next generation of production systems, the concept is being further developed and tested to emerge as a production system paradigm. The essence of evolvability resides not only in the ability of system components to adapt to the changing conditions of operation, but also to assist in the evolution of these components in time. Characteristically, Evolvable systems have distributed control, and are composed of intelligent modules with embedded control. To assist the development and life cycle, a methodological framework is being developed.

Purpose – Dimensional variation management is a major challenge in multi-station sheet metal assembly processes involving complex products such as automotive body and aircraft fuselage assemblies. Very few studies have explored it at a preliminary design phase taking into consideration effects of part deformation on variation propagation, since early design phase involves the development of imprecise design models with scant

Design methods for medical rapid prototyping (RP) of personalized cranioplasty implants are presented in this paper. These methods are applicable to model cranioplasty implants for all types of the skull defects including beyondmidline and multiple defects. The methods are based on two types of anatomical data, solid bone models (STereoLithography les -STL) and bone slice contours (Initial Graphics Exchange Speci cation -IGES and StrataSys Layer les -SSL). The bone solids and contours are constructed based on computed tomography scanning data, and these data are generated in medical image processing and STL slicing packages.

Purpose -The purpose of this research is to develop an automatic optical inspection system for thin film transistor (TFT) liquid crystal display (LCD). Design/methodology/approach -A new algorithm that accounts for the closing, opening, etching, dilating, and genetic method is used. It helps to calculate the location and rotation angle for transistor patterns precisely and quickly. The system can adjust inspection platform parameters according to viewed performance. The parameter adaptation occurs in parallel with running the genetic algorithm and imaging processing methods. The proposed method is compared with the algorithms that use artificial parameter sets. Findings -This system ensures high quality in an LCD production line. This multipurpose image-based measurement method uses unsophisticated and economical equipment, and it also detects defects in the micro-fabrication process. Originality/value -The experiment's results show that the proposed method offers advantages over other competing methods.

Purpose-The purpose of this paper is to investigate the process of jamming of the hollow parts on the shaft and to derive a mathematical model for jamming in an assembly process. Design/methodology/approach-The mathematical model for jamming of parts on the shaft in an assembly process is based on the sizes, geometry, angular declination of part and shaft axes, and the frictional factor. Findings-The equation for angular positional tolerance of coaxial parts and shafts, based on their geometry and sizes and leading to jamming, was derived. Research limitations/implications-A mathematical model of parts jamming on the shaft is developed for assembly mechanisms. This research does not consider flexible deformations of components in assembly mechanisms, which results in the axis concentricity of part and shaft in the assembly process. Practical implications-The results presented in the form of angular positional tolerance for coaxial parts and shafts based on their geometry and sizes make it possible to avoid the jamming of the parts. The results allow for formulating the angular positional tolerance of the assembly mechanisms that clamp the parts. Originality/value-The proposed method for calculating the angular positional tolerance of coaxial parts and shafts for the assembly process should allow for increasing the reliability of the assembly process in the manufacturing industry.

Purpose: This paper aims to explore how manufacturers can develop automatic end-of-life processes facilitated by product design methods, e.g. design for disassembly, recycling and remanufacturing. Another aim is to illustrate this kind of product and end-of-life process development while maintaining economic and environmental values. Here, the cases of toner cartridges and liquid crystal displays are the focus. Design/methodology/approach: The research methodology for this paper began with a literature study within the fields of design for automatic recycling and remanufacturing. It also includes the research performed at two different industrial companies using automation in their end-of-life processes. These companies were visited and interviewed several times in order to understand their processes and what current problems they have in automation and product design. Findings: Design implications on the end-of-life have been explored, and in particular, three general product trends are in conflict with automatic disassembly; 1) Products are getting more complex and more heterogeneous, 2) Products are getting sleeker and 3) Products are using more proprietary joints. In addition, the three industrial cases describe different problems in industry and how they can be tackled. Although many manufacturers have adapted the design principles of DFM and DFE, there is still much to improve when it comes to designing for the product's end-of-life processes. These kinds of adaptions should increase in importance over time as more and more products and components are remanufactured and/or material recycled. These kinds of adaptions will also encourage an increase of products passing through more resource efficient end-of-life options. Practical implications: Manufacturers reading what design problems other companies are experiencing and what solutions can be found would facilitate their own businesses and willingness to start their own and/or improve their existing manufacturing business. This could then be in shape developing products for end-of-life processes which also would encourage them to start their own end-of-life process facilities. Social Implications: From a societal perspective, an increase in remanufactured products being placed on the market can increase the awareness and confidence of the consumers in non-new products made from nonvirgin materials. This will increase the market for second-life products and bring about economics of scale, which in turn will alleviate the problem of depletion of resources. Originality/value: Most previous research in this area treats the different end-of-life processes separately; material recycling and product remanufacturing are but two examples. However, in this paper the focus is more on the overall view of end-of-life processes, along with examples of more specific and detailed end-of-life processes such as disassembly and cleaning.

Purpose -The purpose of this paper is to develop a new rectilinear branch pipe-routing algorithm for automatic generation of rectilinear branch pipe routes in constrained spaces of aero-engines. Design/methodology/approach -Rectilinear branch pipe routing that connects multiple terminals in a constrained space with obstacles can be formulated as a rectilinear Steiner minimum tree with obstacles (RSMTO) problem while meeting certain engineering rules, which has been proved to be an NP-hard and discrete problem. This paper presents a discrete particle swarm optimization (PSO) algorithm for rectilinear branch pipe routing (DPSO-RBPRA) problems, which adopts an attraction operator and an energy function to plan the shortest collision-free connecting networks in a discrete graph space. Moreover, this paper integrates several existing techniques to evaluate particles for the RSMTO problem in discrete Manhattan spaces. Further, the DPSO-RBPRA is extended to surface cases to adapt to requirements of routing pipes on the surfaces of aero-engines. Findings -Pipe routing numeral computations show that, DPSO-RBPRA finds satisfactory connecting networks while considering several engineering rules, which demonstrates the effectiveness of the proposed method. Originality/value -This paper applies the Steiner tree theory and develops a DPSO algorithm to plan the aero-engine rectilinear branch pipe-routing layouts.

Today's Internet technology provides a convenient way for us to develop an integrated network environment for the diversified applications of different robotic systems. To be successful in real-world applications, Internet-based robots require a high degree of autonomy and local intelligence to deal with the restricted bandwidth and arbitrary transmission delay of the Internet. This paper describes the first step toward building such an Internet-based robotic system for teleoperation in the University of Essex. The system has a standard network protocol and an interactive human-machine interface. Using a Web browser, a remote operator can control the mobile robot to navigate in our laboratory with visual feedback and a simulated environment map via the Internet. The employment of an intuitive user interface enables Internet users to control the mobile robot and implement useful tasks remotely. Although at its first stage, the developed system has the potential to be extended to many real-world applications such as tele-manufacturing, tele-training and tele-service.

... In the marker-less registration method, the camera pose is estimated by the four specified points. ... cs.unc.edu/ , geom/V_COLLIDE/, last accessed April 2005) has been implemented in the prototypeAR assembly feature ... Figure 12 shows the collision detection experimental result. ...

Purpose – In this study, a new methodology to evaluate the performance of physics simulation engines (PSEs) when used in haptic virtual assembly applications is proposed. This methodology can be used to assess the performance of any physics engine. To prove the feasibility of the proposed methodology, two-third party PSEs – Bullet and PhysXtm – were evaluated. The paper aims to discuss these issues. Design/methodology/approach – Eight assembly tests comprising variable geometric and dynamic complexity were conducted. The strengths and weaknesses of each simulation engine for haptic virtual assembly were identified by measuring different parameters such as task completion time, influence of weight perception and force feedback. Findings – The proposed tests have led to the development of a standard methodology by which physics engines can be compared and evaluated. The results have shown that when the assembly comprises complex shapes, Bullet has better performance than PhysX. It was...

Purpose -The purpose of this paper is to develop a new rectilinear branch pipe-routing algorithm for automatic generation of rectilinear branch pipe routes in constrained spaces of aero-engines. Design/methodology/approach -Rectilinear branch pipe routing that connects multiple terminals in a constrained space with obstacles can be formulated as a rectilinear Steiner minimum tree with obstacles (RSMTO) problem while meeting certain engineering rules, which has been proved to be an NP-hard and discrete problem. This paper presents a discrete particle swarm optimization (PSO) algorithm for rectilinear branch pipe routing (DPSO-RBPRA) problems, which adopts an attraction operator and an energy function to plan the shortest collision-free connecting networks in a discrete graph space. Moreover, this paper integrates several existing techniques to evaluate particles for the RSMTO problem in discrete Manhattan spaces. Further, the DPSO-RBPRA is extended to surface cases to adapt to requirements of routing pipes on the surfaces of aero-engines. Findings -Pipe routing numeral computations show that, DPSO-RBPRA finds satisfactory connecting networks while considering several engineering rules, which demonstrates the effectiveness of the proposed method. Originality/value -This paper applies the Steiner tree theory and develops a DPSO algorithm to plan the aero-engine rectilinear branch pipe-routing layouts.

Because of the intense competition in the current global economy, a company must conceive, design, and manufacture new products quickly and inexpensively. The design cycle can be shortened through simulation. Rapid technical advances in many different areas of scientific computing provide the enabling technologies for creating a comprehensive simulation and visualization environment for assembly design and planning. We have built an intelligent environment in which simple simulation tools can be composed into complex simulations for detecting potential assembly problems. Our goal in this research is to develop high fidelity assembly simulation and visualization tools that can detect assembly related problems without going through physical mock-ups. In addition, these tools can be used to create easy-to-visualize instructions for performing assembly and service operations.

One of the key factors for success in assembly automation at present is the ability of system integrators to deliver more reliable and customised systems within shorter periods of time. Despite the active research in the development of distributed engineering support systems, there is a clear need for practical methods and tools to support the interactions between different stakeholders at the early product and assembly system design stages. This paper reports on the development of assembly process and equipment data models using context free grammars. The models enable a web-based decision-making for formation of assembly workstations using distributed linguistic approach.

Purpose -The objective of this paper is to propose a solution framework for better project delivery control. Design/methodology/approach -Three emerging technologies that may offer practical solutions are reviewed. These are: automatic product identification, merge-in-transit (MIT), and agent based control systems. Findings -Combining project site level and shipment specific control makes it possible to implement MIT in the project delivery chain. This basic functionality of merging deliveries is needed to react to project delays, and improve rescheduling project resources. Research limitations/implications -Systems design and trials are needed for further development of the proposed solution framework. Practical implications -Organizations responsible for coordinating project deliveries need to think about the incentives and costs for logistics service providers, and other business partners to participate in MIT solutions. Originality/value -The proposed framework is based on an open identification scheme. This makes it possible for new project delivery partners and service providers to locate and start using the controlling software applications without prior notification and arrangement.

Purpose This paper aims to propose a combined methodology to help decision makers in evaluating and selecting the most effective part feeding system. Design/methodology/approach As a first step of the methodology, a hierarchical clustering analysis is applied to design a kitting or hybrid feeding system. Second, activity-based costing methodology is applied to determine which system is better according to their costs. Besides, sensitivity analysis is implemented to observe the behavior of the system in case of the takt time changes. Findings Using kitting systems purely can lead to problems because of the big and expensive parts in the mixed-model assembly systems. Therefore, the hybrid feeding policy can provide better solutions for such systems. Research limitations/implications A case study is conducted in a company and the most produced product of the company is considered to design the part feeding system. Results indicated that transportation cost has a large proportion on the...

Purpose – The purpose of this paper is to explain the development and testing of a condition-monitoring sub-module of an integrated plant maintenance management application based on artificial intelligence (AI) techniques, mainly knowledge-based systems, having several modules, sub-modules and sections. Design/methodology/approach – The approach is applicable to general purpose machinery. A maintenance knowledge base is developed from published information on

Purpose This paper aims to propose a combined methodology to help decision makers in evaluating and selecting the most effective part feeding system. Design/methodology/approach As a first step of the methodology, a hierarchical clustering analysis is applied to design a kitting or hybrid feeding system. Second, activity-based costing methodology is applied to determine which system is better according to their costs. Besides, sensitivity analysis is implemented to observe the behavior of the system in case of the takt time changes. Findings Using kitting systems purely can lead to problems because of the big and expensive parts in the mixed-model assembly systems. Therefore, the hybrid feeding policy can provide better solutions for such systems. Research limitations/implications A case study is conducted in a company and the most produced product of the company is considered to design the part feeding system. Results indicated that transportation cost has a large proportion on the...

Page 1. Research article Simple assembly line balancing problem under the combinations of the effects of learning and deterioration M. Duran Toksarı Industrial Engineering Department, Engineering Faculty, Erciyes University, Kayseri, Turkey ...

Mastering high-density optical disks, like the Blu-raye disk, requires new equipment design. Active magnetic bearing technology seem well suitable for this purpose, but challenges arise in obtaining the required extreme accuracy. Creating a very low mechanical coupling between the system and the external world is the potential solution to this challenge pursued in this paper. Design considerations on actuators, amplifiers, sensors and overall design are discussed and the system performance is predicted using an error-budgeting estimation. This prediction indicates the feasibility of the concept, while the first prototype has been assembled and is being tested.

Purpose -Laser milling is a non-conventional layer-by-layer material removal technology suitable for machining a wide range of materials. This technology is particularly suitable to produce microstructures inside cavities, also obtained by other conventional processes, though with larger material removal rates, or for the direct development of microcavities not requiring high removal rates. This paper seeks to evaluate the capacity of laser milling for manufacturing of mould inserts. Design/methodology/approach -The paper examined several specific features of laser milling, important for the manufacturing of mould inserts, such as walls verticality, unselected illuminating areas, due to an incorrect STL removal volume definition, aspiration process and orientation, to prevent welding of re-solidified particles on the surface. Two mould inserts were produced too, assembled on a metallic mould frame and tested with different injection conditions. Findings -The findings suggest that laser milling is a suitable technology to produce small mould insert for injection moulding, though injection conditions are different as one moves from macroscopic to microscopic injected parts. New design guidelines must be undertaken jointly with the assessment of laser milling performance to make mould microcavities. One of the major difficulties of this process is to keep the side walls vertical plus the generation of undesirable machined volumes, due to unselected illuminating areas below the STL volume, corresponding to the volume to be removed, whenever laser milling is used to operate with structures previously machined. To prevent welding of re-solidified particles on the surface a proper aspiration must also be considered. Originality/value -The paper describes the benefits of laser milling technology.

One of the key factors for success in assembly automation at present is the ability of system integrators to deliver more reliable and customised systems within shorter periods of time. Despite the active research in the development of distributed engineering support systems, there is a clear need for practical methods and tools to support the interactions between different stakeholders at the early product and assembly system design stages. This paper reports on the development of assembly process and equipment data models using context free grammars. The models enable a web-based decision-making for formation of assembly workstations using distributed linguistic approach.

An Improved discrete particle swarm optimization (DPSO)-based algorithm for the traveling salesman problem (TSP) is proposed. In order to overcome the problem of premature convergence, a novel depressor is proposed and a diversity measure to control the swarm is also introduced which can be used to switch between the attractor and depressor. The proposed algorithm has been applied to a set of benchmark problems and compared with the existing algorithms for solving TSP using swarm intelligence. The results show that it can prevent premature convergence to a high degree, but still keeps a rapid convergence like the basic DPSO.

Purpose -Evolvable production systems enable fully reconfiguration capabilities on the shop floor through process-oriented modularity and multiagent-based distributed control. To be able to benefit architectural and operational characteristics of evolvable systems, there is a need of a new planning approach which links shop floor characteristics and planning operations. This paper seeks to address these issues. Design/methodology/approach -Evolvable production system has a structured methodology in itself. Consistent to this, a reference planning architecture is developed aiming to achieve agility on planning activities. Besides a workload control method is proposed and implemented as a part of the planning architecture. Findings -First applications of evolvable systems have been implemented through European research projects. Shop floor working principles and architectural characteristics are consistent to facilitate more agility on planning activities which are framed at a planning reference architecture called demand responsive planning. As an implementation case, an agent-based workload control method is proposed and implemented. The characteristics of EPS and proposed planning architecture enable continuous and dynamic workload control of the shop floor to be implemented. Originality/value -This paper presents a new planning model compatible with evolvable production systems targeting to agility to demand on planning and control activities benefiting shop floor enhancements of a fully reconfigurable system which enables to relax constraints imposed from production systems to planning. In addition, a continuous and dynamic workload control method is proposed and implemented.

Purpose This paper aims to propose a combined methodology to help decision makers in evaluating and selecting the most effective part feeding system. Design/methodology/approach As a first step of the methodology, a hierarchical clustering analysis is applied to design a kitting or hybrid feeding system. Second, activity-based costing methodology is applied to determine which system is better according to their costs. Besides, sensitivity analysis is implemented to observe the behavior of the system in case of the takt time changes. Findings Using kitting systems purely can lead to problems because of the big and expensive parts in the mixed-model assembly systems. Therefore, the hybrid feeding policy can provide better solutions for such systems. Research limitations/implications A case study is conducted in a company and the most produced product of the company is considered to design the part feeding system. Results indicated that transportation cost has a large proportion on the...

Purpose – This paper aims to consider a multi-site production planning problem with failure in rework and breakdown subject to demand uncertainty. Design/methodology/approach – In this new mathematical model, at first, a feasible range for production time is found, and then the model is rewritten considering the demand uncertainty and robust optimization techniques. Here, three evolutionary methods are presented: robust particle swarm optimization, robust genetic algorithm (RGA) and robust simulated annealing with the ability of handling uncertainties. Firstly, the proposed mathematical model is validated by solving a problem in the LINGO environment. Afterwards, to compare and find the efficiency of the proposed evolutionary methods, some large-size test problems are solved. Findings – The results show that the proposed models can prepare a promising approach to fulfill an efficient production planning in multi-site production planning. Results obtained by comparing the three propo...

In all areas of science and engineering, applied researchers shoulder a tremendous responsibility, in that, through their work, they demonstrate the discipline's relevance to the betterment of humankind's quality and quantity of life. It is well understood that failure to do so successfully will inevitably lead to the demise of the discipline. Machine or artificial vision is a subdiscipline of computer vision that deals with its application in industrial settings. In machine vision, researchers draw from fundamental advances in a multitude of fields, ...

Purpose-The purpose of this paper is to address a problem that is commonly faced by manufacturing companies in the plastics industry, where large and different batches of freshly produced units need to be unloaded from the injection-moulding machines and relocated, using automation. Design/methodology/approach-The new solution is reached through a formal design approach, including a function analysis, a product design specification, a quality function deployment exercise, the generation of a number of conceptual solutions, and concept evaluation using morphological charts, failure mode and effect analysis and a decision matrix. Findings-A single modular end effector that can be easily reconfigured for a large variety of moulds has been developed. The results are also extrapolated to more general applications where an end effector is required to carry out simultaneously several different but well-defined functions in the presence of high variety. Research limitations/implications-The critical decision that often needs to be made in industry, between flexibility and reconfigurability, is discussed. It is shown that when batch sizes are large, the penalty incurred in reconfiguration time is well offset by gains in simplicity, reliability and lower cost. Practical implications-The company involved in this case study will achieve significant savings in costs and in storage space, since it will no longer need dedicated gripping devices for its different products. Originality/value-This paper demonstrates the application of a formal design and development approach to arrive at a novel reconfigurable solution to a common parts handling problem in industry.

The growing complexity of industrial robot work-cells calls for the use of advanced orchestration techniques to promote flexibility and reusability. This paper presents a solution based on service-oriented platforms that endorses the separation of concerns, coordination and execution. The execution is kept inside each individual device and their functionality is exposed via automatic generation of services. The orchestration is performed in a cell controller that uses a state-chart engine to achieve the cell behaviour. The statecharts defined for this engine are work-cell programs without implicit dependencies on the services and therefore reusable and easily maintainable. From the early evaluations made in this paper the SCXML based purposed language is more adapted to the industrial robotic cell scenario than existing alternatives. The generation of services allow the integration without knowledge of any programming language.