Optimização do processo de fabrico de componentes para a indústria automóvel

A qualidade é um factor-chave na indústria automóvel. Todos os fornecedores de componentes para a indústria automóvel estão sujeitos a qualificações e auditorias sistemáticas, com vista a melhorar os processos e verificar a sua rastreabilidade. Quando os processos assentam essencialmente em mão-de-obra intensiva, torna-se muito mais difícil atingir a ambicionada meta dos zero-defeitos, e a garantia da qualidade pode ficar comprometida, sendo necessário instalar procedimentos de controlo mais apurados. No entanto, se o processo ou processos forem convenientemente definidos, e se optar por capital intensivo em detrimento da mão-de-obra intensiva, a garantia da qualidade pode ser uma realidade, podendo ser fortemente minimizadas as operações de controlo da qualidade. Este trabalho teve por base a necessidade de reduzir fortemente, ou eliminar mesmo, o aparecimento de defeitos de montagem num sistema designado por remachado. Após cuidada análise do processo instalado, já parcialmente automatizado, mas ainda fortemente dependente de mão-de-obra, procedeu-se ao projecto de um equipamento capaz de reproduzir o mesmo efeito, mas que acomodasse alguns possíveis defeitos oriundos dos fornecedores dos componentes que são inseridos neste conjunto, colocados a montante na cadeia de fornecimento do produto. O equipamento resultante deste trabalho permitiu baixar o tempo de ciclo, acomodar a variabilidade dimensional detectada nos componentes que constituem o conjunto e reduzir drasticamente o número de não-conformidades.

Melhoria/simplificação ergonómica de linhas de montagem

Hoje em dia, com os avanços constantes na indústria, novas áreas começam cada vez mais a ser foco de atenção por parte das organizações. Motivados pela procura de melhores condições para os seus colaboradores e por todos os benefícios que este tipo de intervenção oferece, tanto a curto, como principalmente a médio e longo prazo, a Grohe Portugal, mais especificamente o seu departamento de montagem, achou relevante potenciar a aplicação da Ergonomia nos seus postos de trabalho. Posto isto, esta dissertação pretende apresentar o trabalho desenvolvido junto da organização que teve como objetivo projetar e executar uma linha de montagem que tivesse em consideração os seguintes aspetos: • Ergonomia; • Automatização ou semi-automatização de operações; • Simplificação de aspetos operacionais; • Sistemas de abastecimento mais robustos e de fácil uso; • Simplificação de setups; • Definição de dimensões normalizadas para futuros projetos. As soluções encontradas tiveram como objetivo primordial satisfazer o maior número possível de colaboradores, sendo que para tal foram utilizados dados referentes a antropometria da população Portuguesa. Para a realização e conclusão deste projeto, o trabalho foi decomposto em varias etapas, de entre as quais se destacam: • Analise e estudo dos métodos de montagem; • Levantamento de todos os componentes e operações que constituem o processo de fabrico das diversas famílias onde foram implementados novos projetos; • Definição e uniformização da estrutura das novas linhas de montagem; • Estudo e definição da disposição dos componentes na nova linha, bem como da sua forma de abastecimento; • Projeto da linha de montagem em 3D com recurso ao software SolidWorks (DassaultSystemes, 2014); • Montagem final da linha, bem como o acompanhamento da sua fase de arranque. Durante o estagio foi ainda pensado e implementado um projeto paralelo com vista a constante manutenção e melhoria do departamento de montagem cujo objetivo, através de “plant walks”, e detetar de entre outras, situações de falta de identificação de componentes ou equipamentos, degradação de ferramentas, fugas ou derrames nas linhas, etc. O balanco final do trabalho foi bastante positivo, tendo-se alcançado melhorias em alguns índices de qualidade, tempos de abastecimento e condições ergonómicas dos postos de trabalho que sofreram intervenção, tendo essas melhorias resultado numa avaliação positiva por parte dos colaboradores que integram essas mesmas linhas.

The influence of task design on upper limb muscles fatigue during low-load repetitive work: A systematic review

Ergonomic interventions such as increased scheduled breaks or job rotation have been proposed to reduce upper limb muscle fatigue in repetitive low-load work. This review was performed to summarize and analyze the studies investigating the effect of job rotation and work-rest schemes, as well as, work pace, cycle time and duty cycle, on upper limb muscle fatigue. The effects of these work organization factors on subjective fatigue or discomfort were also analyzed. This review was based on relevant articles published in PubMed, Scopus and Web of Science. The studies included in this review were performed in humans and assessed muscle fatigue in upper limbs. 14 articles were included in the systematic review. Few studies were performed in a real work environment and the most common methods used to assess muscle fatigue were surface electromyography (EMG). No consistent results were found related to the effects of job rotation on muscle activity and subjective measurements of fatigue. Rest breaks had some positive effects, particularly in perceived discomfort. The increase in work pace reveals a higher muscular load in specific muscles. The duration of experiments and characteristics of participants appear to be the factors that most have influenced the results. Future research should be focused on the improvement of the experimental protocols and instrumentation, in order to the outcomes represent adequately the actual working conditions. Relevance to industry: Introducing more physical workload variation in low-load repetitive work is considered an effective ergonomic intervention against muscle fatigue and musculoskeletal disorders in industry. Results will be useful to identify the need of future research, which will eventually lead to the adoption of best industrial work practices according to the workers capabilities.

Design and Development of a Solar Dryer for Microalgae Retrieval - An EPS@ISEP 2013 Spring Project

Currently excessive fossil fuel consumption has become a serious problem. People are searching for new solutions of energy production and there are several options to obtain alternative sources of energy without further devastating the already destroyed environment. One of these solutions is growing microalgae, from which biodiesel can be obtained. The microalgae production is a growing business because of its many useful compounds. In order to collect these compounds microalgae must first be harvested and then dried. Nowadays the solutions used for drying use too much energy and therefore are too expensive and not sustainable. The goal of this project, one of the possible choices during the EPS@ISEP 2013 Spring, was to develop a solar microalgae dryer. The multinational team involved in its development was composed of five students, from distinct countries and fields of study, and was the responsible for designing a solar microalgae dryer prototype for the microalgae laboratory of the chemical engineering department at ISEP, suitable for future tests and incorporating control process (in order not to destroy the microalgae during the drying process). The solar microalgae dryer was built to work as a distiller that gets rid of the excess water from the microalgae suspension. This paper presents a possible solution for this problem, the steps to create the device to harvest the microalgae by drying them with the use of solar energy (also used as an energy source for the solar dryer control system), the technologies used to build the solar microalgae dryer, and the benefits it presents compared to current solutions. It also presents the device from the ethical and sustainable viewpoint. Such alternative to already existing methods is competitive as far as energy usage is concerned.

Design and Implementation of a Biologically Inspired Flying Robot - An EPS@ISEP 2014 Spring Project

The goal of this EPS@ISEP project proposed in the Spring of 2014 was to develop a flapping wing flying robot. The project was embraced by a multinational team composed of four students from different countries and fields of study. The team designed and implemented a robot inspired by a biplane design, constructed from lightweight materials and battery powered. The prototype, called MyBird, was built with a 250 € budget, reuse existing materials as well as low cost solutions. Although the team's initial idea was to build a light radio controlled robot, time limitations along with setbacks involving the required electrical components led to a light but not radio controlled prototype. The team, from the experience gathered, made a number of future improvement suggestions, namely, the addition of radio control and a camera and the adoption of articulated monoplane design instead of the current biplane design for the wings.

Design and Implementation of a Biologically Inspired Swimming Robot - An EPS@ISEP 2014 Spring Project

This paper presents the development of a fish-like robot called Bro-Fish. Bro-Fish aims to be an educational toy dedicated to teaching mechanics, programming and the physics of floating objects to youngsters. The underlying intention is to awaken the interest of children for technology, especially biomimetic (biologically inspired) approaches, in order to promote sustainability and raise the level of ecological awareness. The main focus of this project was to create a robot with carangiform locomotion and controllable swimming, providing the opportunity to customize parts and experiment with the physics of floating objects. Therefore, the locomotion principles of fishes and mechanisms developed in related projects were analysed. Inspired by this background knowledge, a prototype was designed and implemented. The main achievement is the new tail mechanism that propels the robot. The tail resembles the undulation motion of fish bodies and is actuated in an innovative way, triggered by an elegant movement of a rotating helicoidal. First experimental tests revealed the potential of the proposed methodology to effectively generate forward propulsion.

Optimizing potentiometric ionophore and electrode design for environmental on-site control of antibiotic drugs: Application to sulfamethoxazole

Potentiometric sensors are typically unable to carry out on-site monitoring of environmental drug contaminants because of their high limits of detection (LODs). Designing a novel ligand material for the target analyte and managing the composition of the internal reference solution have been the strategies employed here to produce for the first time a potentiometric-based direct reading method for an environmental drug contaminant. This concept has been applied to sulfamethoxazole (SMX), one of the many antibiotics used in aquaculture practices that may occur in environmental waters. The novel ligand has been produced by imprinting SMX on the surface of graphitic carbon nanostructures (CN) < 500 nm. The imprinted carbon nanostructures (ICN) were dispersed in plasticizer and entrapped in a PVC matrix that included (or not) a small amount of a lipophilic additive. The membrane composition was optimized on solid-contact electrodes, allowing near-Nernstian responses down to 5.2 μg/mL and detecting 1.6 μg/mL. The membranes offered good selectivity against most of the ionic compounds in environmental water. The best membrane cocktail was applied on the smaller end of a 1000 μL micropipette tip made of polypropylene. The tip was then filled with inner reference solution containing SMX and chlorate (as interfering compound). The corresponding concentrations were studied for 1 × 10−5 to 1 × 10−10 and 1 × 10−3 to 1 × 10−8 mol/L. The best condition allowed the detection of 5.92 ng/L (or 2.3 × 10−8 mol/L) SMX for a sub-Nernstian slope of −40.3 mV/decade from 5.0 × 10−8 to 2.4 × 10−5 mol/L.

Rapid automated method for on-site determination of sulfadiazine in fish farming: a stainless steel veterinary syringe coated with a selective membrane of PVC serving as a potentiometric detector in a flow-injection-analysis system

Sulfadiazine is an antibiotic of the sulfonamide group and is used as a veterinary drug in fish farming. Monitoring it in the tanks is fundamental to control the applied doses and avoid environmental dissemination. Pursuing this goal, we included a novel potentiometric design in a flow-injection assembly. The electrode body was a stainless steel needle veterinary syringe of 0.8-mm inner diameter. A selective membrane of PVC acted as a sensory surface. Its composition, the length of the electrode, and other flow variables were optimized. The best performance was obtained for sensors of 1.5-cm length and a membrane composition of 33% PVC, 66% onitrophenyloctyl ether, 1% ion exchanger, and a small amount of a cationic additive. It exhibited Nernstian slopes of 61.0 mV decade-1 down to 1.0×10-5 mol L-1, with a limit of detection of 3.1×10-6 mol L-1 in flowing media. All necessary pH/ionic strength adjustments were performed online by merging the sample plug with a buffer carrier of 4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid, pH 4.9. The sensor exhibited the advantages of a fast response time (less than 15 s), long operational lifetime (60 days), and good selectivity for chloride, nitrite, acetate, tartrate, citrate, and ascorbate. The flow setup was successfully applied to the analysis of aquaculture waters. The analytical results were validated against those obtained with liquid chromatography–tandem mass spectrometry procedures. The sampling rate was about 84 samples per hour and recoveries ranged from 95.9 to 106.9%.

ROAZ and ROAZ II Autonomous Surface Vehicle Design and Implementation

International Lifesaving Congress 2007, La Coruna, Spain, December, 2007

ROAZ Autonomous Surface Vehicle Design and Implementation

The design of an Autonomous Surface Vehicle for operation in river and estuarine scenarios is presented. Multiple operations with autonomous underwater vehicles and support to AUV missions are one of the main design goals in the ROAZ system. The mechanical design issues are discussed. Hardware, software and implementation status are described along with the control and navigation system architecture. Some preliminary test results concerning a custom developed thruster are presented along with hydrodynamic drag calculations by the use of computer fluid dynamic methods.

Design of the ISePorto robocup Middle-Size League Robotic Soccer Team: Control, Localisation and Coordination

Proceedings of the 10th Mediterranean Conference on Control and Automation - MED2002 Lisbon, Portugal, July 9-12, 2002

A New ROV Design: Issues on Low Drag and Mechanical Symmetry

This paper reports the design of a new remotely operated underwater vehicle (ROV), which has been developed at the Underwater Systems and Technology Laboratory (USTL) - University of Porto. This design is contextualized on the KOS project (Kits for underwater operations). The main issues addressed here concern directional drag minimization, symmetry, optimized thruster positioning, stability and layout of ROV components. This design is aimed at optimizing ROV performance for a set of different operational scenarios. This is achieved through modular configurations which are optimized for each different scenario.

A Fractional Calculus Perspective in the Evolutionary Design of Combinational Circuits

This paper analyses the performance of a genetic algorithm (GA) in the synthesis of digital circuits using two novel approaches. The first concept consists in improving the static fitness function by including a discontinuity evaluation. The measure of variability in the error of the Boolean table has similarities with the function continuity issue in classical calculus. The second concept extends the static fitness by introducing a fractional-order dynamical evaluation.

Design of Digital Fractional-Order Integrators and Differentiators by Least Squares

First IFAC Workshop on Fractional Differentiation and Its Application - 19-21 July 2004, Enseirb, Bordeaux, France - FDA'04

Simple Kinematic Design for Evading the Forced Oscillation of a Car-Wheel Suspension System

An adaptive control damping the forced vibration of a car while passing along a bumpy road is investigated. It is based on a simple kinematic description of the desired behavior of the damped system. A modified PID controller containing an approximation of Caputo’s fractional derivative suppresses the high-frequency components related to the bumps and dips, while the low frequency part of passing hills/valleys are strictly traced. Neither a complete dynamic model of the car nor ’a priori’ information on the surface of the road is needed. The adaptive control realizes this kinematic design in spite of the existence of dynamically coupled, excitable internal degrees of freedom. The method is investigated via Scicos-based simulation in the case of a paradigm. It was found that both adaptivity and fractional order derivatives are essential parts of the control that can keep the vibration of the load at bay without directly controlling its motion.