A manual of electro-metallurgy : including the applications of the art to manufacturing processes /

Includes index.

Investigative framework for research into the design of manufacturing processes

This paper is based a major research project run by a team from the Innovation, Design and Operations Management Research Unit at the Aston Business School under SERC funding. International Computers Limited (!CL), the UK's largest indigenous manufacturer of mainframe computer products, was the main industrial collaborator in the research. During the period 1985-89 an integrated production system termed the "Modular Assembly Cascade'' was introduced to the Company's mainframe assembly plant at Ashton-under-Lyne near Manchester. Using a methodology primarily based upon 'participative observation', the researchers developed a model for analysing this manufacturing system design called "DRAMA". Following a critique of the existing literature on Manufacturing Strategy, this paper will describe the basic DRAMA model and its development from an industry specific design methodology to DRAMA II, a generic model for studying organizational decision processes in the design and implementation of production systems. From this, the potential contribution of the DRAMA model to the existing knowledge on the process of manufacturing system design will be apparent.

Reliability modelling and verification of manufacturing processes based on process knowledge management

Reliability modelling and verification is indispensable in modern manufacturing, especially for product development risk reduction. Based on the discussion of the deficiencies of traditional reliability modelling methods for process reliability, a novel modelling method is presented herein that draws upon a knowledge network of process scenarios based on the analytic network process (ANP). An integration framework of manufacturing process reliability and product quality is presented together with a product development and reliability verification process. According to the roles of key characteristics (KCs) in manufacturing processes, KCs are organised into four clusters, that is, product KCs, material KCs, operation KCs and equipment KCs, which represent the process knowledge network of manufacturing processes. A mathematical model and algorithm is developed for calculating the reliability requirements of KCs with respect to different manufacturing process scenarios. A case study on valve-sleeve component manufacturing is provided as an application example of the new reliability modelling and verification procedure. This methodology is applied in the valve-sleeve component manufacturing processes to manage and deploy production resources.

Automatització d'un bombo de rentar i condicionar taps de suro

El projecte es centra en l’automatització d’una màquina que permeti desenvolupar elsprocessos de rentar i igualat de taps suro, exercint el control i la gestió dels processos.La finalitat d’aquesta automatització es tracta en generar una interfície fàcil de fer servir pera governar la màquina, que permeti: treballar tant en mode manual com en automàtic, peròamb restriccions que puguin evitar possibles errors en la manipulació d’aquesta que puguinespatllar la matèria prima carregada al interior del cistell. Amb la possibilitat de posardiferents receptes de tractaments de rentat, modificables en funció de la necessitat detreball.Tots aquests punts permetran millorar el rendiments de treball de la màquina reduint elstemps morts, i limitant la possibilitat de fer errors en els processos a aplicar, punt moltimportant degut al cost elevat del material a tractar

Disseny i desenvolupament d’un sistema tecnològic de fabricació de “stents” cardiovasculars mitjançant làser

Els stents són unes pròtesis endovasculars. L’objectiu del projecte és el disseny i desenvolupament d’un utillatge que permeti la seva fabricació per tall làser. S’utilitzarà el làser del GREP (Grup de Recerca en Enginyeria de Producte, Procés i Producció) de la Universitat de Girona, el qual està instal•lat sobre el capçal d’un centre de mecanitzat convencional

Influence of process parameters on part quality and mechanical properties for DMLS and SLM with iron-based materials

Rapid manufacturing is an advanced manufacturing technology based on layer-by-layer manufacturing to produce a part. This paper presents experimental work carried out to investigate the effects of scan speed, layer thickness, and building direction on the following part features: dimensional error, surface roughness, and mechanical properties for DMLS with DS H20 powder and SLM with CL 20 powder (1.4404/AISI 316L). Findings were evaluated using ANOVA analysis. According to the experimental results, build direction has a significant effect on part quality, in terms of dimensional error and surface roughness. For the SLM process, the build direction has no influence on mechanical properties. Results of this research support industry estimating part quality and mechanical properties before the production of parts with additive manufacturing, using iron-based powders

Degradation of all-inkjet-printed organic thin-film transistors with TIPS-pentacene under processes applied in textile manufacturing

Printed electronics represent an alternative solution for the manufacturing of low-temperature and large area flexible electronics. The use of inkjet printing is showing major advantages when compared to other established printing technologies such as, gravure, screen or offset printing, allowing the reduction of manufacturing costs due to its efficient material usage and the direct-writing approach without requirement of any masks. However, several technological restrictions for printed electronics can hinder its application potential, e.g. the device stability under atmospheric or even more stringent conditions. Here, we study the influence of specific mechanical, chemical, and temperature treatments usually appearing in manufacturing processes for textiles on the electrical performance of all-inkjet-printed organic thin-film transistors (OTFTs). Therefore, OTFTs where manufactured with silver electrodes, a UV curable dielectric, and 6,13-bis(triisopropylsilylethynyl) pentance (TIPS-pentacene) as the active semiconductor layer. All the layers were deposited using inkjet printing. After electrical characterization of the printed OTFTs, a simple encapsulation method was applied followed by the degradation study allowing a comparison of the electrical performance of treated and not treated OTFTs. Industrial calendering, dyeing, washing and stentering were selected as typical textile processes and treatment methods for the printed OTFTs. It is shown that the all-inkjet-printed OTFTs fabricated in this work are functional after their submission to the textiles processes but with degradation in the electrical performance, exhibiting higher degradation in the OTFTs with shorter channel lengths (L=10 μm).

Monitoring Directed Energy Deposition Processes in Additive Manufacturing

The purpose of this study is to find out how laser based Directed Energy Deposition processes can benefit from different types of monitoring. DED is a type of additive manufacturing process, where parts are manufactured in layers by using metallic powder or metallic wire. DED processes can be used to manufacture parts that are not possible to manufacture with conventional manufacturing processes, when adding new geometries to existing parts or when wanting to minimize the scrap material that would result from machining the part. The aim of this study is to find out why laser based DED-processes are monitored, how they are monitored and what devices are used for monitoring. This study has been done in the form of a literature review. During the manufacturing process, the DED-process is highly sensitive to different disturbances such as fluctuations in laser absorption, powder feed rate, temperature, humidity or the reflectivity of the melt pool. These fluctuations can cause fluctuations in the size of the melt pool or its temperature. The variations in the size of the melt pool have an effect on the thickness of individual layers, which have a direct impact on the final surface quality and dimensional accuracy of the parts. By collecting data from these fluctuations and adjusting the laser power in real-time, the size of the melt pool and its temperature can be kept within a specified range that leads to significant improvements in the manufacturing quality. The main areas of monitoring can be divided into the monitoring of the powder feed rate, the temperature of the melt pool, the height of the melt pool and the geometry of the melt pool. Monitoring the powder feed rate is important when depositing different material compositions. Monitoring the temperature of the melt pool can give information about the microstructure and mechanical properties of the part. Monitoring the height and the geometry of the melt pool is an important factor in achieving the desired dimensional accuracy of the part. By combining multiple different monitoring devices, the amount of fluctuations that can be controlled will be increased. In addition, by combining additive manufacturing with machining, the benefits of both processes could be utilized.

Computer vision in aseptic pharmaceutical manufacturing: a deep learning-based approach to vial inspection and pack formation during a lyophilizer loading cycle

Vision systems are powerful tools playing an increasingly important role in modern industry, to detect errors and maintain product standards. With the enlarged availability of affordable industrial cameras, computer vision algorithms have been increasingly applied in industrial manufacturing processes monitoring. Until a few years ago, industrial computer vision applications relied only on ad-hoc algorithms designed for the specific object and acquisition setup being monitored, with a strong focus on co-designing the acquisition and processing pipeline. Deep learning has overcome these limits providing greater flexibility and faster re-configuration. In this work, the process to be inspected consists in vials’ pack formation entering a freeze-dryer, which is a common scenario in pharmaceutical active ingredient packaging lines. To ensure that the machine produces proper packs, a vision system is installed at the entrance of the freeze-dryer to detect eventual anomalies with execution times compatible with the production specifications. Other constraints come from sterility and safety standards required in pharmaceutical manufacturing. This work presents an overview about the production line, with particular focus on the vision system designed, and about all trials conducted to obtain the final performance. Transfer learning, alleviating the requirement for a large number of training data, combined with data augmentation methods, consisting in the generation of synthetic images, were used to effectively increase the performances while reducing the cost of data acquisition and annotation. The proposed vision algorithm is composed by two main subtasks, designed respectively to vials counting and discrepancy detection. The first one was trained on more than 23k vials (about 300 images) and tested on 5k more (about 75 images), whereas 60 training images and 52 testing images were used for the second one.

Innovative manufacturing process for hybrid pultruded products based on cork and polymeric pre-shapes

Pultruded products are being targeted by a growing demand due to its excellent mechanical properties and low chemical reactivity, ensuring a low level of maintenance operations and allowing an easier assembly operation process than equivalent steel bars. In order to improve the mechanical drawing process and solve some acoustic and thermal insulation problems, pultruded pipes of glass fibre reinforced plastics (GFRF) can be filled with special products that increase their performance regarding the issues previously referred. The great challenge of this work was drawing a new equipment able to produce pultruded pipes filled with cork or polymeric pre-shaped bars as a continuous process. The project was carried out successfully and the new equipment was built and integrated in the pultrusion equipment already existing, allowing to obtain news products with higher added-value in the market, covering some needs previously identified in the field of civil construction.

Anthropocentric-based robotic and autonomous systems: assessment for new organisational options

Text based on the paper presented at the Conference "Autonomous systems: inter-relations of technical and societal issues" held at Monte de Caparica (Portugal), Universidade Nova de Lisboa, November, 5th and 6th 2009 and organized by IET-Research Centre on Enterprise and Work Innovation

Projeto mecânico de equipamento para fabrico automatizado de vestuário

O fabrico de vestuário é uma atividade que se desenvolve em Portugal há várias décadas. Existem marcas de vestuário com reconhecimento a nível mundial que são de origem portuguesa. Para se conseguir qualidade é necessário inovar e automatizar determinados processos, de forma a aumentar produtividades e reduzir erros devido à mão de obra de tarefas intensivas. Na empresa Portuguesa Henrique Camões, com uma vasta experiência ligada a equipamentos de fabrico têxtil, nasceu a ideia de projetar um protótipo de um equipamento automatizado para o fabrico de colarinhos e punhos, com a finalidade de verificar a sua viabilidade a nível funcional. Este trabalho teve assim por base a necessidade de efetuar um projeto sobre um equipamento capaz de costurar e cortar colarinhos e punhos, a serem aplicados em peças de vestuário. Inicialmente foi efetuado um estudo prévio de levantamento de equipamentos já existentes para fins semelhantes. Foi então necessário idealizar um equipamento capaz de responder às expectativas e exigências por parte do cliente. Após os esboços iniciais, onde foram definidos os tipos de mecanismos e formas de funcionamento dos diferentes sistemas em função dos movimentos e ações pretendidas e a estrutura do equipamento, estes sistemas foram otimizados por forma a se obter como resultado final um equipamento funcional. Foi também projetado o esquema pneumático e Grafcet de funcionamento do equipamento. Como auxiliares do projeto, apresentam-se a lista de componentes e de processos de fabrico, bem como os desenhos de pormenor de todos os componentes integrantes da estrutura. O resultado final é um conjunto de ideias e soluções possíveis de aplicar num equipamento deste tipo. De facto, a solução proposta é uma possibilidade viável para um equipamento automatizado para costura e corte de colarinhos e punhos.

A comparison of environmental licensing systems in operation in the wood panel manufacturing industry in the Northern Hemisphere

The objective of this thesis is to compare and contrast environmental licensing systems, for the wood panel industry, in a number of countries in order to determine which system is the best from an environmental and economic point of view. The thesis also examines the impact which government can have on industry and the type of licensing system in operation in a country. Initially, the thesis investigates the origins of the various environmental licensing systems which are in operation in Ireland, Scotland, Wales, France, USA and Canada. It then examines the Environmental Agencies which control and supervise industry in these countries. The impact which the type of government (i.e. unitary or federal) in charge in any particular country has on industry and the Regulatory Agency in that country is then described. Most of the mills in the thesis make a product called OSB (Oriented Strand Board) and the manufacturing process is briefly described in order to understand where the various emissions are generated. The main body of the thesis examines a number of environmental parameters which have emission limit values in the licenses examined, although not all of these parameters have emission limit values in all of the licenses. All of these parameters are used as indicators of the potential impact which the mill can have on the environment. They have been set at specific levels by the Environmental Agencies in the individual countries to control the impact of the mill. Following on from this, the two main types of air pollution control equipment (WESPs and RTOs) are described in regard to their function and capabilities. The mill licenses are then presented in the form of results tables which compare air results and water results separately. This is due to the fact that the most significant emission from this type of industry is to air. A matrix system is used to compare the licenses so that the comparison can be as objective as possible. The discussion examines all of the elements previously described and from this it was concluded that the IPC licensing system is the best from an environmental and economic point of view. It is a much more expensive system to operate than the other systems examined, but it is much more comprehensive and looks at the mill as a whole rather than fragmenting it. It was also seen that the type of environmental licensing system which is in place in a country can play a role in the locating of an industry as certain systems were seen to have more stringent standards attached to them. The type of standard in place in a country is in turn influenced by the type of government which is in place in that country.

Automatització d’una màquina de tall rotatiu

Molt sovint, a l’indústria de l’alimentació o de la cosmètica, hi ha promocions on s’afegeixen productes de regal; aquests els embalen amb un sleever (tipus de plàstic força rígid) que després retractilen. Aquestes promocions solen ser esporàdiques i canviants i això fa que no sigui factible la modificació de la línia de producció general per a realitzar-les. Per aquest motiu, moltes empreses disposen d’una petita màquina de tall rotatiu per a poder tallar els sleevers ells mateixos, i així tallar a molta velocitat i precisió aquestes petites produccions. Així doncs, esdevé molt interessant l’adquisició d’aquest tipus de maquinària. L’objectiu del projecte és fer l’automatització d’una màquina que pugui tallar aquest tipus de material ràpidament per fer-lo rentable

Harjateräspulttien tuotannon kehitys eri kustannusympäristöissä

Työssä kartoitettiin eri kierteenvalmistusmenetelmät ja valittiin sopivin vaihtoehto harjateräspulttien kierteiden valmistukseen. Työssä painotettiin etenkin läpimenoaikaa ja työkalukustannuksia. Valitun menetelmän pohjalta suunniteltiin kolme eri automaatiotason tuotantosolua tuotteiden valmistukseen Suomessa ja Slovakiassa sekä laskettiin niiden investointikustannukset ja – hyödyt. Tuotannonsuunnittelussa otettiin huomioon myös muut pultin valmistusvaiheet kierteenvalmistuksen lisäksi sekä selvitettiin nykyisten prosessiparametrien tehokkuus. Työssä löydettiin nykyistä nopeampi ja työkalukustannuksiltaan halvempi menetelmä kierteiden valmistukseen. Myös nykyisiä prosessiparametreja saatiin nopeutettua. Työn pohjalta valittu tuotantosolu päätettiin toteuttaa käytännön testien onnistuessa.