Automated assembly processes

For example, the characteristic dimension A on the cover support leg was critical to the success of the automated assembly process, the potential failure mode being a major disruption to the production line. An FMEA Severity Rating (S) = 8 is allocated. See a Process FMEA Severity Ratings table as provided in Chrysler Corporation et al. (1995) for guidance on process orientated failures. The component cost, Pc = 5.93 and the number planned to be produced per annum, N = 50000. 

Only very recently the production of melt-blown polypropylene fleeces with considerably thinner fiber diameter became possible [100], thus making it possible — a low-cost hydrophilization provided — to achieve attractive properties with regard to small pore size and excellent tensile performance for use in highly automated assembly processes. 

Aerobic adhesives improve productivity of automated assembly processes by curing instantly, but only on demand. 

In the case of automated assembly processes, the general sequence is part insertion followed by the soldering step. (Slightly different steps are used for the paste-in-hole process that is, the paste may be applied before or after part insertion.)... 

Of course, various levels of automation may be considered, depending on production volumes and capital expenditure costs. However, with continued miniaturization of surface-mount products as well as the strict requirements for the repeatable placement of specific solder paste volumes and accurate placement of components, will be a foregone necessity to assemble surface-mount technology with a fuUy automated assembly process. 

Some automated assembly processes can be integrated into the injection molding process. This process is called In-Mold-Assembly and can be realized with double cubes (Figure 1.73) or with a swivel carrier for the molded parts (Figure 1.74). 

Performance of a stack of cells is limited by performance of the weakest cell in stack. It is therefore important to achieve high uniformity in performance of the individual cells in the stack, through stack design, mass production techniques, quality control, and automated stack assembly process. Optimum flow field design may be obtained by careful Computational Fluid Mechanic techniques and experimental validation including flow visualization techniques. 

Another megatrend in this competitive business environment is that all production processes need to be world-class and lean. This means that processes must be automated lead times shortened rework, scrap, and waste minimized or eliminated and less product must appear in inventory. This places a burden on the adhesive formulator in that the products not only must perform in service (e.g., creep resistance, peel strength) but also must perform in the assembly process (e.g., fast cure time, minimal scrap, low energy cure). 

Packaging and/or assembly Process integration and automation Cabling... 

Table 2 Automated Molecular Assembly Process Workstations...

The new UV curable silicones afford an attractive alternative to standard heat activated materials for integrated circuit protection where high speed automated fabrication and assembly processes are desired. Additionally, the photosensitivity of these materials present other convenient processing opportunities. 

Automated synthesis can ran unattended and is less prone to human error than manual synthesis. As the biopolymer assembly process was automated, there was a tendency to produce longer sequences. This, in turn, required better synthetic methods, which has led to continual improvements in solid-phase chemistries and instrument design. 

Particularly for small annual workpiece amounts, it is economically necessary to assemble several different products or components in one flexible automated assembly system in order to maintain a high level of system utilization. Because sometimes very different assembly processes must be realized, a linking structure (flex-link sequence), independent from certain assembly processes, is necessary. Assembly systems of this type are able to meet the increasing demands for more flexibility. 

The early history of assembly process development is closely related to the history of the development of mass production methods. Thus, the pioneers of mass production are also considered the pioneers of modern assembly. Their ideas and concepts significantly improved the manual and automated assembly methods employed in large-volume production. In the past decade, efforts have been directed at reducing assembly costs by the application of flexible automation and modem techniques. 

When a product is designed, consideration is generally given to the ease of manufacture of its individual parts and the function and the appearance of the final product. One of the first steps in the introduction of automation in the assembly process is to reconsider the design of the product to make it simple enough to be performed by a machine. 

The chief characteristic of electrostatically applied powder polymer is the ability to produce a thin coating. It is the preferred method of producing a coating of 0.001-0.002 in. (0.025-0.050 mm) thickness. It is a continuous process and suited to automated assembly-line production. With a well designed recovery system and fully enclosed spray booth, the process permits full utilization of the powder. The particle size of sprayed powders is smaller than that of powders used in fluidized bed coating. The average particles size is 30-60 microns. 

Automation is the cmiversion of a procedure, a process, or equipment to an automatic operation without intervention by a human operator (CIRP 2004). In the field of assembly, assembly automation describes the cmiversion of a manual assembly process to an assembly without a human operator, fii general, the term describes the process of increasing the number of assembly steps carried out by automatic assembly machines in a plant. 

Product Design for Automated Assembly As the technical and economical feasibility of products depends on the assembly process, an important part of assembly automation is the design for assembly. Hereby the following rules have to be considered (Boothroyd 2005) ... 

The technical installations are configured in a U-shaped line directly side by side, according to the sequence of process steps. Hybrid assembly lines include a semi-automated working station for each assembly process. A control station is suited at the end of the assembly line. 

Sometimes, the manufactured product will actually be an input for another manufacturing operation. We refer to these products as industrial products. For example, an automated manufacturing facility that produces cell phones will assemble parts that have been manufactured at other plants (Figure 16-6). This manufacturing process is really more of an assembly process. 

The cost effectiveness of hollow part processing vs. more conventional constructions will vary considerably according to the application and to the state of the art of the process being applied. The savings associated with molding the part in one piece may be offset by the use of robotics in automating the assembly process coupled with a more effective molding process. 

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