Automotive manufacturing processes. Volume V - manufacturing processes and equipment for the mass production and assembly of motor vehicles. Final report.

National Highway Traffic Safety Administration, Office of Research and Development, Washington, D.C.

Exploring the Use of Everglades Agricultural Area Canal Water as Base Medium for the Mass Production of Algae for Biofuels

Freshwater use is a major concern in the mass production of algae for biofuels. This project examined the use of canal water obtained from the Everglades Agricultural Area as a base medium for the mass production of algae. This water is not suitable for human consumption, and it is currently used for crop irrigation. A variety of canals were found to be suitable for water collection. Comparison of two methods for algal production showed no significant difference in biomass accumulation. It was discovered that synthetic reticulated foam can be used for algal biomass collection and harvest, and there is potential for its application in large-scale operations. Finally, it was determined that high alkaline conditions may help limit contaminants and competing organisms in growing algae cultures.

Quantification of the effects of architectural traits on dry mass production and light interception of tomato canopy under different temperature regimes using a dynamic functional-structural plant model

There is increasing interest in evaluating the environmental effects on crop architectural traits and yield improvement. However, crop models describing the dynamic changes in canopy structure with environmental conditions and the complex interactions between canopy structure, light interception, and dry mass production are only gradually emerging. Using tomato (Solanum lycopersicum L.) as a model crop, a dynamic functional-structural plant model (FSPM) was constructed, parameterized, and evaluated to analyse the effects of temperature on architectural traits, which strongly influence canopy light interception and shoot dry mass. The FSPM predicted the organ growth, organ size, and shoot dry mass over time with high accuracy (>85%). Analyses of this FSPM showed that, in comparison with the reference canopy, shoot dry mass may be affected by leaf angle by as much as 20%, leaf curvature by up to 7%, the leaf length: width ratio by up to 5%, internode length by up to 9%, and curvature ratios and leaf arrangement by up to 6%. Tomato canopies at low temperature had higher canopy density and were more clumped due to higher leaf area and shorter internodes. Interestingly, dry mass production and light interception of the clumped canopy were more sensitive to changes in architectural traits. The complex interactions between architectural traits, canopy light interception, dry mass production, and environmental conditions can be studied by the dynamic FSPM, which may serve as a tool for designing a canopy structure which is 'ideal' in a given environment.

High temperature and vapor pressure deficit aggravate architectural effects but ameliorate non-architectural effects of salinity on dry mass production of tomato

Tomato (Solanum lycopersicum L.) is an important vegetable crop and often cultivated in regions exposed to salinity and high temperatures (HT) which change plant architecture, decrease canopy light interception and disturb physiological functions. However, the long-term effects of salinity and HT combination (S+HT) on plant growth are still unclear. A dynamic functional-structural plant model (FSPM) of tomato was parameterized and evaluated for different levels of S+HT combinations. The evaluated model was used to quantify the contributions of morphological changes (architectural effects) and physiological disturbances (non-architectural effects) on the reduction of shoot dry mass under S+HT. The model predicted architectural variables with high accuracy (>85%), which ensured the reliability of the model analyses. HT enhanced architectural effects but reduced non-architectural effects of salinity on dry mass production. The stronger architectural effects of salinity under HT could not be counterbalanced by the smaller non-architectural effects. Therefore, long-term influences of HT on shoot dry mass under salinity were negative at the whole plant level. Our model analysis highlights the importance of plant architecture at canopy level in studying the plant responses to the environments and shows the merits of dynamic FSPMs as heuristic tools.

Extending light-weighting and mass-production of ultra high strength steels via condition-based maintenance

The use of ultra high strength steels (UHSS) in the automotive industry presents a significant opportunity for continued vehicle light-weighting, due to possible strength-to-weight improvements of three to four times that of conventional sheet steel grades. This performance benefit is achievable whist maintaining most of the advantages of low-cost mass-production associated with the cold stamping of sheet steel for automotive body components. However, the introduction of UHSS can result in significantly increased wear of the stamping tools, which is difficult to predict at the design stage and can lead to unexpected process failure during mass-production. Therefore, there is a need to be able to monitor and predict the onset of severe wear, such that the best course of condition-based maintenance can be scheduled and unscheduled stoppages due to tool wear eradicated. This paper describes a novel active monitoring system that is being developed by researchers at Deakin University, The Australian National University and Ford Motor Company, Asia Pacific and Africa. The aim of the active monitoring system is to detect the initial onset of a change of state, such as wear, through the measurement of variables such as punch force and audio signals. A semi-industrial stamping process, using a progressive die setup and high strength steel sheet with hardened tool steel tooling, is the experimental basis for the initial model and system development.

Application of lean production to reducing operational waste in a tile manufacturing process

Roofing tile manufacturing is a mass production process with high operational and inventory wastes and costs. Due to huge operational costs, excessive inventory and wastes, and quality problems, roofing tile manufacturers are trying to implement lean manufacturing practice in their operations in order to remain competitive in an ncreasingly competitive global market. The aim of this research is to evaluate the possibility of reducing the operational and inventory costs of the tile manufacturing process through waste minimization. This paper analyses the current waste situation in a tile manufacturing process and develops current and future value stream mapping for such a process with a view to implementing lean principles in manufacturing. The focus of the approach is on cost reduction by eliminating non-value-added activities.

Small scale commercial production of tilapia fingerlings in floating bamboo net-hapas

The inadequate supply of tilapia seed is considered as one of the major present constraints to the development of the culture industry in Nigeria. The floating bamboo net-hapa hatchery/nursery system was observed to be very efficient in the mass production of tilapia (Oreochromis niloticus) fry and fingerlings at Kainji Lake Research Institute. This system was therefore, recommended for small-scale (artisanal) commercial operators consisting of fishermen families in order to increase their productivity and hasten development of rural communities. The economic analysis of this system showed that loan obtained for the recommended scale of operation can be amortized within 2 years of the project. It was emphasized that the operational and managerial skills of the fish farm operators account largely to the production cost and profitability of the enterprise

Recent advances in the hatchery production of seed of some commercial bivalves in India

The Central Marine Fisheries Research Institute has established a shellfish hatchery laboratory at its Tuticorin Research Centre with the objective of developing appropriate technology for the production of seed of commercial bivalves. A viable technology was developed for the mass production of the seed of Pinctada fucata, P. margaretifera, Crassostrea madrasensis, Perna indica, P. viridis, Anadara granosa and Meretrix meretrix. The hatchery facility and the technology, comprising brood stock conditioning, induced spawning, larval rearing and seed production are described. In the light of these developments the future outlook is appraised.

Tank cultivation of the red alga Palmaria palmata: Year-round induction of tetrasporangia, tetraspore release in darkness and mass cultivation of vegetative thalli

Field-collected tetrasporophytes of Palmaria palmata were tumbled in 300-L outdoor tanks from January to August at ambient daylength or in a constant short-day (SD) regime (8 h light per day), both at 10 or 15 degrees C. Tetrasporangia were massively induced after 2.5 months under SD conditions at 10 degrees C and completely lacking at 15 degrees C, both under SD or ambient daylength conditions, with a few tetrasporangia present at 10 degrees C and ambient daylength. Elongation rates of tagged tetrasporophytic thalli peaked from March to April in all four conditions, when the biomass densities in the outdoor tanks were close to 2.5 kg fresh weight m(-2). Under all four conditions, juvenile proliferations started to appear in June from the margins of the old fronds, and attained approximately 1 cm in length by the end of July. Approximately 80% of the tetraspores were released during the first three dark phases in a light/dark regime, and the remaining 20% during the light phases. A minimum of 10 min darkness was observed to trigger spore release. White light inhibited tetraspore release, while a similar number of spores were released in continuous red light or in the light/dark regime, although with no significant differences of spore release during subjective days and nights. Sporelings were successfully derived from the released tetraspores for mass propagation of the male gametophyte in 2000-L outdoor tanks in a greenhouse. Mass production of male gametophytic sporelings of P. palmata was completed two times by SD induction of tetrasporangia at 10 degrees C, release of spores in darkness and culturing the sporelings until they were ready to be propagated vegetatively in greenhouse tanks. One experiment lasted from January to October 2001, with spore release in June, and the second from September to April 2003, with spore release in January. These results may support the development of sustainable, year-round Palmaria farming. (c) 2005 Elsevier B.V. All rights reserved.

Scalable production of wrinkled and few-layered graphene sheets and their use for oil and organic solvent absorption

High-quality wrinkled and few-layered graphene sheets have been produced via a mechano-thermal exfoliation process for a simple, effective and low-cost mass production. Graphene sheets were produced by first ball milling of graphite with ammonium chloride followed by thermal annealing at 800 °C in nitrogen gas. The few layered graphene sheets show highly efficient selectivity and capacity for the absorption of petroleum products as well as organic solvents such as ethanol, cyclohexane and chloroform (up to 82, 42 and 98 times of their own weight, respectively). The saturated few-layered graphene sheets can be cleaned for reuse by simply burning in air. The low-cost strategy for mass production and easy recycling routes demonstrate the great potential of few-layered graphene sheets for oil removal.

Scaling up the production rate of nanofibers by needleless electrospinning from multiple ring

Mass production of nanofibers is crucial in both laboratory research and industry application of nanofibers. In this study, multiple ring spinnerets have been used to generate needleless electrospinning. Multiple polymer jets were produced from the top of each ring in the spinning process, resulting in thin and uniform nanofibers. Production rate of nanofibers increased gradually with the increase of the number of rings in the spinneret. Spinning performance of multiple ring electrospinning, namely the quality and production rate of the as-spun nanofibers, was dependent on experimental parameters like applied voltage and polymer concentration. Electric field analysis of multiple ring showed that high concentrated electric field was formed on the surface of each ring. Fiber diameter together with production rate of needleless electrospinning was dependent on the strength and distribution of the electric field of the spinneret. Needleless electrospinning from multiple ring can be further applied in both laboratory research and industry where large amount of nanofibers must be employed simultaneously. © 2014 The Korean Fiber Society and Springer Science+Business Media Dordrecht.

Evaluating irradiation dose for sterility induction and quality control of mass-produced fruit fly Bactrocera tryoni (Diptera : Tephritidae)

The sterile insect technique has been routinely used to eradicate fruit fly Bactrocera tryoni (Froggatt) incursions. This study considers whether fly quality in a mass-rearing facility can be improved by reducing irradiation doses, without sacrificing reproductive sterility. Pupae were exposed to one of five target irradiation dose ranges: 0, 40-45, 50-55, 60-65, and 70-75 Gy. Pupae were then assessed using routine quality control measures: flight ability, sex ratio, longevity under nutritional stress, emergence, and reproductive sterility. Irradiation did not have a significant effect on flight ability or sex ratio tests. Longevity under nutritional stress was significantly increased at 70-75 Gy, but no other doses differed from 0 Gy. Emergence was slightly reduced in the 50-55, 60-65, and 70-75 Gy treatments, but 40-45 Gy treatments did not differ from 0 Gy, though confounding temporal factors complicate interpretation. Reproductive sterility remained acceptable (> 99.5%) for all doses--40-45 Gy (99.78%), 50-55 Gy (100%), 60-65 Gy (100%), and 70-75 Gy (99.99%). We recommend that B. tryoni used in sterile insect technique releases be irradiated at a target dose of 50-55 Gy, providing improved quality and undiminished sterility in comparison with the current 70-75 Gy standard while also providing a substantial buffer against risk of under dosing.

Production technology for entomopathogenic fungus using a biphasic culture system

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