Friday, December 25, 2020

Assembly Automation and Product Design - Boothroyd - Book Information and Related Information

 

Industrial Engineering - Role of Engineering, Mechanization and Automation


In process improvement study or projects, to do a task in the most productive manner, the most efficient manual method (best manual method), best mechanized method and best automation method are to be compared and the most productive method has to be employed. This comparison has to be done at element or suboperation level.

Source: Book: Motion and Time Study: Design and Measurement of Work, Ralph M. Barnes, 7th Edition, Chapter 18. Motion Study, Mechanization, and Automation.

Jidoka - Automation and Mechanization - Process Engineering and Industrial Engineering in Toyota Production System

Jidoka, a pillar of Toyota Production Systems advocates automation with human touch in all operations of a process to increase productivity of operators as well as that of total systems.


Assembly Automation and Product Design - Table of Contents

INTRODUCTION

Historical Development of the Assembly Process

Choice of Assembly Method

Social Effects of Automation

References


AUTOMATIC ASSEMBLY TRANSFER SYSTEMS

Continuous Transfer

Intermittent Transfer

Indexing Mechanisms

Operator-Paced Free-Transfer Machine

References


AUTOMATIC FEEDING AND ORIENTING - VIBRATORY FEEDERS

Mechanics of Vibratory Conveying

Effect of Frequency

Effect of Track Acceleration

Effect of Vibration Angle

Effect of Track Angle

Effect of Coefficient of Friction

Estimating the Mean Conveying Velocity

Load Sensitivity

Solutions to Load Sensitivity

Spiral Elevators

Balanced Feeders

Orientation of Parts

Typical Orienting System

Effect of Active Orienting Devices on Feed Rate

Analysis of Orienting Systems

Performance of an Orienting Device

Natural Resting Aspects of Parts for Automatic Handling

Analysis of a Typical Orienting System

Out-of-Bowl Tooling

References


AUTOMATIC FEEDING AND ORIENTING - MECHANICAL FEEDERS

Reciprocating-Tube Hopper Feeder

Centerboard Hopper Feeder

Reciprocating-Fork Hopper Feeder

External Gate Hopper Feeder

Rotary-Disk Feeder

Centrifugal Hopper Feeder

Stationary-Hook Hopper Feeder

Bladed-Wheel Hopper Feeder

Tumbling-Barrel Hopper Feeder

Rotary-Centerboard Hopper Feeder

Magnetic-Disk Feeder

Elevating Hopper Feeder

Magnetic Elevating Hopper Feeder

Magazines

References


FEED TRACKS, ESCAPEMENTS, PARTS-PLACEMENT MECHANISMS, AND ROBOTS

Gravity Feed Tracks

Powered Feed Tracks

Escapements

Parts-Placing Mechanisms

Assembly Robots

References


PERFORMANCE AND ECONOMICS OF ASSEMBLY SYSTEMS

Indexing Machines

Free-Transfer Machines

Basis for Economic Comparisons of Automation Equipment

Comparison of Indexing and Free-Transfer Machines

Economics of Robot Assembly

References


DESIGN FOR MANUAL ASSEMBLY

Introduction

Where Design for Assembly Fits in the Design Process

General Design Guidelines for Manual Assembly

Development of a Systematic DFA Analysis Method

DFA Index

Classification System for Manual Handling

Classification System for Manual Insertion and Fastening

Effect of Part Symmetry on Handling Time

Effect of Part Thickness and Size on Handling Time

Effect of Weight on Handling Time

Parts Requiring Two Hands for Manipulation

Effects of Combinations of Factors

Threaded Fasteners

Effects of Holding Down

Problems with Manual Assembly Time Standards

Application of the DFA Method

Further General Design Guidelines

References


PRODUCT DESIGN FOR HIGH-SPEED AUTOMATIC ASSEMBLY AND ROBOT ASSEMBLY

Introduction

Design of Parts for High-Speed Feeding and Orienting

Example

Additional Feeding Difficulties

High-Speed Automatic Insertion

Example

Analysis of an Assembly

General Rules for Product Design for Automation

Design of Parts for Feeding and Orienting

Summary of Design Rules for High-Speed Automatic Assembly

Product Design for Robot Assembly

References


PRINTED-CIRCUIT-BOARD ASSEMBLY

Introduction

Terminology

Assembly Process for PCBs

SMD Technology

Estimation of PCB Assembly Costs

Worksheet and Database for PCB Assembly Cost Analysis

PCB Assembly - Equations and Data for Total Operation Cost

Glossary of Terms

References


FEASIBILITY STUDY FOR ASSEMBLY AUTOMATION

Machine Design Factors to Reduce Machine Downtime

Due to Defective Parts

Feasibility Study

References

Problems


Appendix A: Simple Method for the Determination of the Coefficient of Dynamic Friction

The Method

Analysis

Precision of the Method

Discussion

Reference


Appendix B: Out-of-Phase Vibratory Conveyors

Out-of-Phase Conveying

Practical Applications

Reference


Appendix C: Laboratory Experiments

Performance of a Vibratory-Bowl Feeder

Performance of a Horizontal-Delivery Gravity Feed Track

Conclusions


Appendix D: Feeding and Orienting Techniques for Small Parts

Coding System

Feeding and Orienting Techniques

Orienting Devices for Vibratory-Bowl Feeders

Nonvibratory Feeders

Nomenclature

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