Automaattisen robottityösolun suunnittelu – vaihtoehtojen vertailu

The purpose of this thesis was to research the possibilities of adding automation on the product finalization stage of the production of plastic products in Finncont Oy. At the beginning of this thesis work practically all of the finalization work was conducted manually with mostly hand held tools. On the same time, the company was starting to feel pressure to automate some of the production processes; partly due to financial concerns and partly due to company image concerns. Some customers had even expressed their wishes for more automation in Finncont’s production system. During the project, product and production system analysis was conducted on the products of Finncont Oy. The analysis included reviewing product data such as drawings and work instructions and production data, mainly production volumes. A time study was performed for 10 most potential products. Concurrently to the product analysis a literature review was conducted on production systems, layouts and production processes. Based on the results of the product analysis and the literature review, two product groups were formed and three work cell designs were made. Two for group 1 and one for group 2

MAGSEAL Edge Breaking Safety Device

Team 22 was approached by the Magnetic Seal Corporation to solve a problem: develop simple electro-mechanical safety guarding for an edge-breaking and chamfering lathe. To accomplish this, the current situation was thoroughly researched, the machine inspected by the team, and a preliminary patent search conducted to survey the current body of knowledge for machine guarding. Through lessons learned from this literature search, including mounting methods, shape considerations, and a means to electrically link the guard engagement to machine operation, 120 concepts were generated by the team and classified into four groups. A Quality Function Deployment comparison was performed and in addition to sponsor feedback, a preliminary design for the guard was modeled, drawn, and prototyped. This design uses a steel frame to hold interchangeable polycarbonate panes with three con- toured holes cut therein. One hole is provided for the operator to break the outside diameter of a part, another hole expressly for the inside diameter, and a relief by which a grinding wheel can approach and apply a chamfer feature into the part at variable angles. The holes are arranged and sized so that an operator cannot fit both edge-breaking stone and finger at once, and were a slip to occur, the hand would naturally move either against the frame wherein the pane would prevent contact, or away from the machine entirely. Aluminum sheathing is used to fully enclose the operation and prevent egress of debris or dust into the operator area. A two pin support approach was theorized, but not prototyped, for attachment of the guard to the machine. Through inspection of this prototype and simulation within a faithful 3-D replica of the edge-breaking machine, this design was verified to fulfill MAGSEAL\u27s requirements. The use of the safety guard will not increase cycle time and hypothesized to not be an inconvenience to the operator. Additional work will be carried out to fit the device to the lathe, incorporate electrical integration into the power system, and adapt the guard to the full range of processed parts

Medium Duty Gas-Turbine Engine Blade Removal Tool

Solar Turbines Incorporated sponsored a team of three Cal Poly Undergraduate Mechanical Engineering students to design, manufacture, prototype, and test a tool for the removal of turbine blades from their respective disk assembly without damaging the disk itself. The tool was developed for Solar’s industrial gas turbine engines. The tool complies with all OSHA and Solar Turbines safety and engineering constraints, and was designed for use in a shop facility. The tool was made adaptable for geometric variances in multiple turbine rotor disk stages, and requires no more than one technician to operate using a maximum of two shop resources. The tool stands alone on its own fixture, with ease of portability and disassembly in mind. A discrete process was developed to assist in the transition from the current blade removal process to the new blade removal process. In doing so, future disk damage can be prevented by developing a tool and process used to replace the current rudimentary techniques for blade removal

Mad Jack Alpine Touring Model Design

Skiing is a sport enjoyed by millions of people every year, yet ski boots are very uncomfortable and cost- prohibitive, resulting in a low conversion rate of first-time skiers to lifetime skiers. Additionally, Alpine Touring (AT) is seeing a surge in popularity as ski resorts become more expensive, but few companies are developing affordable products in this realm. Mad Jack Snow Sports has developed a product that they believe addresses some of the main issues associated with skiing, but they want to develop their product line further. The problem statement and scope state that the purpose of this project is to develop an Alpine Touring model of the Mad Jack product, redesign the foot and shin pads on the existing Mad Jack model, test the current model to assign a stiffness rating, and improve upon the current forward stiffness. After establishing the scope, brainstormed ideas went through a selection process to choose design changes that would best fulfill the objectives listed in our scope of work. A prototype model was created utilizing existing components from Mad Jack and manufactured components from the team. Additive manufacturing was utilized to prototype geometry to check for ISO compliance. The prototype was tested alongside the existing model to determine increased stiffness. An increase of roughly 0.9 lbf-ft/deg was seen but a design flaw was displayed in a strap deforming. A slight design modification was made, and initial qualitative test showed promising results. The team was unable to test this new model due to the timing of the project. Overall, the project was successful in its goals and recommendations for further design and testing were also passed on

Професійна технічна термінологія у галузі машинобудування

Рецензенти: Д. В. Криворучко – доктор технічних наук, доцент, професор кафедри технології машинобудування, верстатів та інструментів Сумського державного університету; В. І. Шатоха – доктор технічних наук, професор, проректор із науково-педагогічної роботи Національної металургійної академії України.Навчальний посібник є важливою формою міждисциплінарної та міжвузівської інтеграції, створений для зацікавлення студентів у якісному та поглибленому вивченні спеціальних дисциплін та професійної англійської мови, розвитку вмінь самостійної роботи і навичок при написанні та оформленні науково-дослідних робіт, активізації пізнавальної й дослідницької діяльності, стимулює наукові пошуки, обмін досвідом засобами англійської мови у галузі машинобудування. Навчальний посібник призначений для інженерно-технічних і науково-педагогічних працівників, аспірантів і студентів інженерних спеціальностей вищих навчальних закладів.Розроблено в рамках виконання проекту Темпус «Модернізація вищої інженерної освіти в Грузії, Україні та Узбекистані відповідно до технологічних викликів» (ENGITEC 530244-TEMPUS-1-2012-1-SE-TEMPUS-JPCR

Професійна технічна термінологія у галузі машинобудування

Рецензенти: Д. В. Криворучко – доктор технічних наук, доцент, професор кафедри технології машинобудування, верстатів та інструментів Сумського державного університету; В. І. Шатоха – доктор технічних наук, професор, проректор із науково-педагогічної роботи Національної металургійної академії України.Навчальний посібник є важливою формою міждисциплінарної та міжвузівської інтеграції, створений для зацікавлення студентів у якісному та поглибленому вивченні спеціальних дисциплін та професійної англійської мови, розвитку вмінь самостійної роботи і навичок при написанні та оформленні науково-дослідних робіт, активізації пізнавальної й дослідницької діяльності, стимулює наукові пошуки, обмін досвідом засобами англійської мови у галузі машинобудування. Навчальний посібник призначений для інженерно-технічних і науково-педагогічних працівників, аспірантів і студентів інженерних спеціальностей вищих навчальних закладів.Розроблено в рамках виконання проекту Темпус «Модернізація вищої інженерної освіти в Грузії, Україні та Узбекистані відповідно до технологічних викликів» (ENGITEC 530244-TEMPUS-1-2012-1-SE-TEMPUS-JPCR

The Federal Conference on Intelligent Processing Equipment

Research and development projects involving intelligent processing equipment within the following U.S. agencies are addressed: Department of Agriculture, Department of Commerce, Department of Energy, Department of Defense, Environmental Protection Agency, Federal Emergency Management Agency, NASA, National Institutes of Health, and the National Science Foundation

Investigating Sustainable Fuel Effects on Mixing and Combustion through Design and Development of a Gasoline Direct Injection Optically Accessible Engine

Due to ever-growing sustainability issues, more demanding exhaust emission regulations are imposed on internal combustion engines. There is growing introduction of full electrification but, as there are practical issues regarding the full electrification, internal combustion engines are proven to be still useful and often coupled with electric motors. It is, therefore, vital to establish detailed understandings of in-cylinder combustion processes so that the release of greenhouse gas and production of pollutant emissions can be reduced and minimised. Therefore, novel fuels, such as second-generation biofuels, are thoroughly studied to explore possible use as future fuels for hybrid gasoline direct injection powertrains which are derived from sustainable feedstock and provide efficient energy release. For this project, a novel optical engine was designed that facilitate easy access to the piston and rapid cleaning of the piston crown window. A state-of-the-art gasoline direct injection engine was selected for hybrid applications. The initial design of the optical engine was modified to resolve the slackness in the extended timing chains. As the optical engine adopted the Bowditch system and only number 1 cylinder operated, various auxiliary components were also designed and developed to accommodate optical systems and oil circulation, and consider the change in the crankshaft balancing and volume of the air intake. Furthermore, an external fuel supply system was designed to enable a use of different fuels, while minimising a risk of damaging or contaminating the conventional fuel supply lines, by allowing easy cleaning processes. To quantitatively compare the difference in both spray and combustion images between various fuels, MATLAB codes were developed to process the captured images from a high-speed camera. Seven fuels were tested namely gasoline, ethanol, acetic acid, anisole, guaiacol, 2-MF and 2-MTHF; one a reference fossil fuel, one a first-generation biofuel and five second-generation biofuels, respectively. Three different injection timings were applied to simulate stratified, quasi-homogeneous and homogeneous states at low and high injection pressures for combustion studies, with only the injection pressure varied for the constant injection timing at the stratified spray studies. In general, injection pressure did not have a significant effect on soot formation, with exception for anisole, with injection timing found to be the dominant factor. Ethanol showed a similar spray development pattern to that of gasoline but displayed narrower sprays around the injector tip and became wider towards the spark plug. Acetic acid showed an indistinctive spray pattern and all six sprays merged together to form a cloud of fuel. Anisole showed wider sprays than gasoline and ethanol, but exhibited a similar penetration rate. Guaiacol exhibited similar spray characteristics to that of acetic acid, in that it formed a fuel cloud rather than maintaining distinct fuel sprays. Both 2-MF and 2-MTHF showed wide sprays

A framework to support automation in manufacturing through the study of process variability

In manufacturing, automation has replaced many dangerous, mundane, arduous and routine manual operations, for example, transportation of heavy parts, stamping of large parts, repetitive welding and bolt fastening. However, skilled operators still carry out critical manual processes in various industries such as aerospace, automotive and heavy-machinery. As automation technology progresses through more flexible and intelligent systems, the potential for these processes to be automated increases. However, the decision to undertake automation is a complex one, involving consideration of many factors such as return of investment, health and safety, life cycle impact, competitive advantage, and resources and technology availability. A key challenge to manufacturing automation is the ability to adapt to process variability. In manufacturing processes, human operators apply their skills to adapt to variability, in order to meet the product and process specifications or requirements. This thesis is focussed on understanding the ‎variability involved in these manual processes, and how it may influence the automation solution. ‎ Two manual industrial processes in polishing and de-burring of high-value components were observed to evaluate the extent of the variability and how the operators applied their skills to overcome it. Based on the findings from the literature and process studies, a framework was developed to categorise variability in manual manufacturing processes and to suggest a level of automation for the tasks in the processes, based on scores and weights given to the parameters by the user. The novelty of this research lies in the creation of a framework to categorise and evaluate process variability, suggesting an appropriate level of automation. The framework uses five attributes of processes; inputs, outputs, strategy, time and requirements and twelve parameters (quantity, range or interval of variability, interdependency, diversification, number of alternatives, number of actions, patterned actions, concurrency, time restriction, sensorial domain, cognitive requisite and physical requisites) to evaluate variability inherent in the process. The level of automation suggested is obtained through a system of scores and weights for each parameter. The weights were calculated using Analytical Hierarchical Process (AHP) with the help of three experts in manufacturing processes. Finally, this framework was validated through its application to two processes consisting of a lab-based peg-in-a-hole manual process and an industrial process on welding. In addition, the framework was further applied to three processes (two industrial processes and one process simulated in the laboratory) by two subjects for each process to verify the consistency of the results obtained. The results suggest that the framework is robust when applied by different subjects, presenting high similarity in outputs. Moreover, the framework was found to be effective when characterising variability present in the processes where it was applied. The framework was developed and tested in manufacturing of high value components, with high potential to be applied to processes in other industries, for instance, automotive, heavy machinery, pharmaceutical or electronic components, although this would need further investigation. Thus, future work would include the application of the framework in processes in other industries, hence enhancing its robustness and widening its scope of applicability. Additionally, a database would be created to assess the correlation between process variability and the level of automation