Soft Computing Methods in Metallurgy

In metallurgic plants a high quality metal production is always required. Nowadays soft computing applications are more often used for automation of manufacturing process and quality control instead of mechanical techniques. In this thesis an overview of soft computing methods presents. As an example of soft computing application, an effective model of fuzzy expert system for the automotive quality control of steel degassing process was developed. The purpose of this work is to describe the fuzzy relations as quality hypersurfaces by varying number of linguistic variables and fuzzy sets.

Dynamiikan simulointi avoauton tuotekehityksessä

Työn tarkoituksena on perehdyttää Valmet Automotive Oy:n tuotekehitysosastoa dynamiikan simuloinnin perusperiaatteisiin ja kehittää osastolle tulevaisuuden toimintamalli, jossa dynamiikan simulointi on strategisena osa-alueena tuotekehitysprosessissa. Dynamiikan simuloinnin periaatteita käsitellään teoriaosan avulla ja selvitetään kahden eri menetelmän, MBS-simuloinnin ja eksplisiittisen FE-analyysin soveltuvuutta analysointikeinona. Tutkitaan, mihin kohteisiin dynamiikan simulointia voitaisiin tuotekehitysosastolla käyttää ja esitetään toimintatavat kehitettyjen sovelluskohteiden analysoimiseksi. Lisäksi työssä kartoitetaan olemassa olevia dynamiikan simulointiohjelmistoja, joista potentiaalisimpia koekäytetään sovelluskohteisiin ja tuotekehityskeskuksen CAE-järjestelmään soveltuvuuden tarkistamiseksi. Dynamiikan simuloinnista saatavien hyötynäkökohtien perusteella ehdotetaan yritykselle jatkotoimenpiteitä.

Tuotekehityksen toimintolaskenta - Case Oy Sisu Auto Ab

Tutkielman tavoitteena oli tutkia toimintolaskennan soveltuvuutta tuotekehitys-kustannusten selvittämiseen ja kohdistamiseen tuotteiden katelaskennassa. Tarkoitus oli selvittää erityisesti laskennan hyödyt kuorma-autotehtaan kannalta ja rakentaa yritykselle valmis malli tuotekehityskustannusten toimintopohjaiselle laskennalle. Tutkielma on luonteeltaan konstruktiivinen case-tutkimus. Yritykselle pyrittiin teorian pohjalta luomaan käytännön ongelmaan ratkaisu rakentamalla toimintolaskentamalli, jolla yrityksen tuotekehityksen kustannukset pystytään mahdollisimman hyvin jakamaan tuotteille. Mallin rakennuksen myötä saavutettiin selkeät periaatteet kustannusten kohdistamiseen kuorma-autoille. Laskennan avulla saatujen tulosten perusteella saatiin tärkeää tuotekehitystä koskevaa tietoa, jota aikaisemmin ei oltu yrityksessä pystytty hyödyntämään tuotteiden kustannuslaskennassa. Tuloksia on mahdollisuus hyödyntää sekä operatiivisessa että strategisessa päätöksenteossa. Tutkimuksen tuloksia on tarkasteltava tieteellisesti suhteellisen suppeana, juuri kyseiseen yritykseen soveltuvana ratkaisuna.

Variaciones dimensionales en piezas plásticas de inyección y análisis de los medios de control

En la industria de la automoción, así como en todas las que se dedican a fabricar piezas, ya sean plásticas o de otros materiales, es tan importante la Producción como la Calidad. No sirve de nada fabricar mucho si no son piezas de una calidad adecuada, y del mismo modo no es rentable fabricar muy poco volumen por mucho que tenga una calidad excelente. Por ello hay que buscar siempre el equilibrio entre ambos conceptos. La finalidad es tener procesos lo más robustos posibles que nos permitan fabricar cantidad con una buena calidad. La finalidad de este trabajo es buscar los parámetros que más afectan en un proceso de inyección, es decir, saber cuáles son los que debemos tener bajo control para lograr una calidad de piezas buena y un proceso estable y controlado. Para ver si el proceso es capaz de lograr ese objetivo utilizamos gráficos basados en la teoría de 6- sigma que nos calculan el coeficiente de capacidad del proceso (Cpk). A su vez analizaremos los sistemas de medida que utilizamos en cada una de las piezas analizadas para evaluar si son los correctos y nos permiten discriminar piezas buenas de malas en el proceso productivo. La conclusión del trabajo es que hay que prestar especial atención en controlar aquellos aspectos de un proceso que nos aportan variación, y no invertir tiempo ni dinero en aquellos otros que no nos aportan valor añadido y que no afectan sustancialmente al proceso. Este análisis por supuesto lleva su coste, que he analizado y plasmado en las conclusiones para saber lo que le cuesta aproximadamente a una empresa realizarlo.

The initial oxidation of transition metal surfaces

Due to their numerous novel technological applications ranging from the example of exhaust catalysts in the automotive industry to the catalytic production of hydro- gen, surface reactions on transition metal substrates have become to be one of the most essential subjects within the surface science community. Although numerous applications exist, there are many details in the different processes that, after many decades of research, remain unknown. There are perhaps as many applications for the corrosion resistant materials such as stainless steels. A thorough knowledge of the details of the simplest reactions occuring on the surfaces, such as oxidation, play a key role in the design of better catalysts, or corrosion resistant materials in the future. This thesis examines the oxidation of metal surfaces from a computational point of view mostly concentrating on copper as a model material. Oxidation is studied from the initial oxidation to the oxygen precovered surface. Important parameters for the initial sticking and dissociation are obtained. The saturation layer is thoroughly studied and the calculated results arecompared with available experimental results. On the saturated surface, some open questions still remain. The present calculations demonstrate, that the saturated part of the surface is excluded from being chemically reactive towards the oxygen molecules. The results suggest, that the reason for the chemical activity of the saturated surface is due to a strain effect occuring between the saturated areas of the surface.

The effects of some variables on CO2 laser-MAG hybrid welding

The CO2-laser-MAG hybrid welding process has been shown to be a productive choice for the welding industry, being used in e.g. the shipbuilding, pipe and beam manufacturing, and automotive industries. It provides an opportunity to increase the productivity of welding of joints containing air gaps compared with autogenous laser beam welding, with associated reductions in distortion and marked increases in welding speeds and penetration in comparison with both arc and autogenous laser welding. The literature study indicated that the phenomena of laser hybrid welding are mostly being studied using bead-on-plate welding or zero air gap configurations. This study shows it very clearly that the CO2 laser-MAG hybrid welding process is completely different, when there is a groove with an air gap. As in case of industrial use it is excepted that welding is performed for non-zero grooves, this study is of great importance for industrial applications. The results of this study indicate that by using a 6 kW CO2 laser-MAG hybrid welding process, the welding speed may also be increased if an air gap is present in the joint. Experimental trials indicated that the welding speed may be increased by 30-82% when compared with bead-on-plate welding, or welding of a joint with no air gap i.e. a joint prepared as optimum for autogenous laser welding. This study demonstrates very clearly, that the separation of the different processes, as well as the relative configurations of the processes (arc leading or trailing) affect welding performance significantly. These matters influence the droplet size and therefore the metal transfer mode, which in turn determined the resulting weld quality and the ability to bridge air gaps. Welding in bead-onplate mode, or of an I butt joint containing no air gap joint is facilitated by using a leading torch. This is due to the preheating effect of the arc, which increases the absorptivity of the work piece to the laser beam, enabling greater penetration and the use of higher welding speeds. With an air gap present, air gap bridging is more effectively achieved by using a trailing torch because of the lower arc power needed, the wider arc, and the movement of droplets predominantly towards the joint edges. The experiments showed, that the mode of metal transfer has a marked effect on gap bridgeability. Transfer of a single droplet per arc pulse may not be desirable if an air gap is present, because most of the droplets are directed towards the middle of the joint where no base material is present. In such cases, undercut is observed. Pulsed globular and rotational metal transfer modes enable molten metal to also be transferred to the joint edges, and are therefore superior metal transfer modes when bridging air gaps. It was also found very obvious, that process separation is an important factor in gap bridgeability. If process separation is too large, the resulting weld often exhibits sagging, or no weld may be formed at all as a result of the reduced interaction between the component processes. In contrast, if the processes are too close to one another, the processing region contains excess molten metal that may create difficulties for the keyhole to remain open. When the distance is optimised - i.e. a separation of 0-4 mm in this study, depending on the welding speed and beam-arc configuration - the processes act together, creating beneficial synergistic effects. The optimum process separation when using a trailing torch was found to be shorter (0-2 mm) than when a leading torch is used (2-4 mm); a result of the facilitation of weld pool motion when the latter configuration is adopted. This study demonstrates, that the MAG process used has a strong effect on the CO2-laser-MAG hybrid welding process. The laser beam welding component is relatively stable and easy to manage, with only two principal processing parameters (power and welding speed) needing to be adjusted. In contrast, the MAG process has a large number of processing parameters to optimise, all of which play an important role in the interaction between the laser beam and the arc. The parameters used for traditional MAG welding are often not optimal in achieving the most appropriate mode of metal transfer, and weld quality in laser hybrid welding, and must be optimised if the full range of benefits provided by hybrid welding are to be realised.

Autoteollisuus Itä-Euroopassa

Työssä tarkastellaan Itä-Euroopan autoteollisuutta ja pyritään selvittämään, miksi autoteollisuus on siirtänyt valmistustaan Itä-Eurooppaan. Lisäksi arvioidaan, miten autoteollisuus on onnistunut investoinneissaan ja pohditaan, miten autoteollisuuden investoinnit ovat vaikuttaneet sekä kohdemaihin että autoyhtiöihin. Työ on rajattu käsittelemään pääasiallisesti henkilöautojen valmistusta Unkarissa, Puolassa, Romaniassa, Slovakiassa ja Tshekissä. Autoteollisuuden siirtyminen Itä-Eurooppaan tapahtui kahdessa aallossa. Ensimmäiset yritykset perustivat tehtaan epävakaaseen liiketoimintaympäristöön jo heti kommunismin romahdettua. Tällöin houkuttimena oli erityisesti edullinen työvoima. Toisessa aallossa saapuivat aasialaiset autotehtaat 2000-luvulla. Nykyisin autoyhtiöt perustelevat sijoituksiaan alueen kasvavalla kysynnällä. Kuitenkin nyt vaikuttaa siltä, että suuntaus olisi muuttumassa ja uudet tehdasinvestoinnit kohdistuisivat Aasian kasvaville markkinoille.

When supply travels far beyond demand: Causes of oversupply in Spain’s transport infrastructure

Spain’s transport infrastructure policy has become a paradigmatic case of oversupply and of mismatch with demand. The massive expansion of the country’s transport infrastructure over the last decade has not been a response to demand bottlenecks or previously identified needs. For this reason, the intensity of use today on all interurban modes of transport in Spain falls well below that of other EU countries. This paper analyzes the institutional and regulatory factors that have permitted this policy, allowing us to draw lessons from the Spanish case that should help other countries avoid the pitfalls and shortcomings of Spanish policy.

When supply travels far beyond demand: Causes of oversupply in Spain’s transport infrastructure

Spain’s transport infrastructure policy has become a paradigmatic case of oversupply and of mismatch with demand. The massive expansion of the country’s transport infrastructure over the last decade has not been a response to demand bottlenecks or previously identified needs. For this reason, the intensity of use today on all interurban modes of transport in Spain falls well below that of other EU countries. This paper analyzes the institutional and regulatory factors that have permitted this policy, allowing us to draw lessons from the Spanish case that should help other countries avoid the pitfalls and shortcomings of Spanish policy.

When supply travels far beyond demand: Institutional and regulatory causes of oversupply in Spain’s transport infrastructure

Spain’s transport infrastructure policy has become a paradigmatic case of oversupply and of mismatch with demand. The massive expansion of the country’s transport infrastructure over the last decade has not been a response to demand bottlenecks or previously identified needs. For this reason, the intensity of use today on all interurban modes of transport in Spain falls well below that of other EU countries. This paper analyzes the institutional and regulatory factors that have permitted this policy, allowing us to draw lessons from the Spanish case that should help other countries avoid the pitfalls and shortcomings of Spanish policy. Based on our analysis, we also discuss policy remedies and suggest reforms in different regulatory areas, which could help improve the performance of Spain’s infrastructure policy.

Forensic aspects of the weathering and ageing of spray paints

This paper presents a preliminary study on the degradation of spray paint samples, illustrated by Optical, FTIR and Raman measurements. As opposed to automotive paints which are specifically designed for improved outdoor exposure and protected using hindered amine light absorbers (HALS) and ultra-violet absorbers (UVA), the spray paints on their side are much simpler in composition and very likely to suffer more from joint effects of solar radiation, temperature and humidity. Six different spray paint were exposed to outdoor UV-radiation for a total period of three months and both FTIR and Raman measurements were taken systematically during this time. These results were later compared to an artificial degradation using a climate chamber. For infrared spectroscopy, degradation curves were plotted using the photo-oxidation index (POI), and could be successfully approximated with a logarithmic fitting (R2 > 0.8). The degradation can appear after the first few days of exposure and be important until 2 months, where it stabilizes and follow a more linear trend afterwards. One advantage is that the degradation products appeared almost exclusively at the far end (∼3000 cm−1) of mid-infrared spectra, and that the fingerprint region of the spectra remained stable over the studied period of time. Raman results suggest that the pigments on the other side, are much more stable and have not shown any sign of degradation over the time of this study. Considering the forensic implications of this environmental degradation, care should be taken when comparing samples if weathering is an option (e.g. an exposed graffiti compared to the paint from a fresh spray paint can). Degradation issues should be kept in mind as they may induce significant differences between paint samples of common origin.

Privatization and PPPS in transportation infrastructure: Network effects of increasing user fees

PPPS: Problem: Public-private-partnerships in transport infrastructure characteristically increase user-fees. Purpose: We aim to identify the network effects of the use of PPPs and increased user tolls in road infrastructure. Methods: We study the increases in user tolls on motorways due to the use of PPPs in the US. Results and conclusions: Among other things, the monetization of motorways is associated with an increase in toll levels that has consequences for their users, and also for the rest of the sections of the network.

Flash Memory Cells Reliability Parameters Investigation

The present work is a part of the large project with purpose to qualify the Flash memory for automotive application using a standardized test and measurement flow. High memory reliability and data retention are the most critical parameters in this application. The current work covers the functional tests and data retention test. The purpose of the data retention test is to obtain the data retention parameters of the designed memory, i.e. the maximum time of information storage at specified conditions without critical charge leakage. For this purpose the charge leakage from the cells, which results in decrease of cells threshold voltage, was measured after a long-time hightemperature treatment at several temperatures. The amount of lost charge for each temperature was used to calculate the Arrhenius constant and activation energy for the discharge process. With this data, the discharge of the cells at different temperatures during long time can be predicted and the probability of data loss after years can be calculated. The memory chips, investigated in this work, were 0.035 μm CMOS Flash memory testchips, designed for further use in the Systems-on-Chips for automotive electronics.

Impacto dos catalisadores automotivos no controle da qualidade do ar

Advanced industrialized nations have experienced severe pollution problems over the past forty years, caused mainly by carbon monoxide, hydrocarbons and nitrogen oxide emissions from automobiles. Catalyst technology has played a major part in minimizing these emissions as required by even more restrictive laws. The catalyst has been optimized over the years to meet the requirements of high activity and long life. The oxidation of hydrocarbon and carbon monoxide are in advanced development stage while that of NOx catalysts is far less advanced. In the future, catalyst technology is expected to contribute to overcome the challenges to get a cleaner air.

Pla de màrqueting per al llançament d'un nou producte en el mercat dels motors elèctrics per a bancs de proves

Ningú no dubte ja del canvi de mentalitat que s’ha produït en els darrers anys en els compradors pel què fa al mercat de l’automòbil. La seguretat i el respecte per el medi ambient, són actualment dos dels factors claus que el consumidor té en compte a l’hora de comprar un vehicle. D’altra banda en els darrers anys la Unió Europea, ha fixat tota una sèrie normatives per tal de reduir les emissions nocives a l’atmosfera. Així doncs, més seguretat i menys emissions, signifiquen vehicles que incorporin components i sistemas cada cop més sofisticats, els quals, a la vegada, necessiten de bancs d’assaig i equips de test per tal de ser validats. Aquest fet ha provocat una revolució dins dels sistemes de test per a vehicles, per als quals han augmentat enormement les exigències en quan a precisions i repetibilitat per tal d’intentar reproduir, amb la màxima fiabilitat possible, les condicions de treball que hauran de suportar els components durant el seu ús real. Les característiques dels motors elèctrics, resulten ideals per a accionar aquest tipus d’aplicacions, ja que permeten un control del parell molt acurat i una repetibilitat quasi perfecte enfront d’altres sistemas utilitzats fins no fa massa temps. Aquesta demanda creixent d’aquest tipus de màquines elèctriques, obra una nova oportunitat de negoci per a les empreses fabricants de motors elèctrics. L’objectiu principal d’aquest treball és identificar i satisfer les necessitats dels clients, dins d’un mercat industrial concret: el mercat dels motors elèctrics per a bancs de proves de components per a la indústria de l’automoció. La fita és doncs la de proporcionar les eines necessàries per tal de que una empresa, fabricant de motors elèctrics de velocitat variable, pugui realitzar el disseny, desenvolupament i llançament comercial d’un nou tipus de motor, específicament pensat per aquest mercat, amb les màximes garanties d’èxit. Com a principal conclusió, el treball argumenta que el nou producte representa una oportunitat de negoci força atractiva i rendible per a l’empresa, i permetrà diversificar la oferta de la companyia cap a un nou sector fins ara no explotat.