Assembly Automation and Product Design

ISBN-10: 1574446436

ISBN-13: 9781574446432

Edition: 2nd 2005 (Revised)

List price: $188.95
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Description:

The design for assembly (DFA) method has become a widely-used way for companies to introduce competitive products at reduced costs. This text looks at both manual and automated assembly processes, considering the benefits of the DFA method for each.
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Book details

List price: $188.95
Edition: 2nd
Copyright year: 2005
Publisher: CRC Press LLC
Publication date: 6/22/2005
Binding: Hardcover
Pages: 536
Size: 6.25" wide x 9.00" long x 1.25" tall
Weight: 1.848
Language: English

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
Orienting System
Method of System Analysis
Optimization
Performance of an Orienting Device
Analysis
Natural Resting Aspects of Parts for Automatic Handling
Assumptions
Analysis for Soft Surfaces
Analysis for Hard Surfaces
Analysis for Cylinders and Prisms with Displaced Centers of Mass
Summary of Results
Analysis of a Typical Orienting System
Design of Orienting Devices
Out-of-Bowl Tooling
References
Automatic Feeding and Orienting - Mechanical Feeders
Reciprocating-Tube Hopper Feeder
General Features
Specific Applications
Centerboard Hopper Feeder
Maximum Track Inclination
Load Sensitivity and Efficiency
Reciprocating-Fork Hopper Feeder
External Gate Hopper Feeder
Feed Rate
Load Sensitivity and Efficiency
Rotary-Disk Feeder
Indexing Rotary-Disk Feeder
Rotary-Disk Feeder with Continuous Drive
Load Sensitivity and Efficiency
Centrifugal Hopper Feeder
Feed Rate
Efficiency
Stationary-Hook Hopper Feeder
Design of the Hook
Feed Rate
Bladed-Wheel Hopper Feeder
Tumbling-Barrel Hopper Feeder
Feed Rate
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
Analysis of Horizontal-Delivery Feed Track
Example
On/Off Sensors
Theory
Feed Track Section
Design of Gravity Feed Tracks for Headed Parts
Analysis
Results
Procedure for Use of Figure 5.17 to Figure 5.20
Powered Feed Tracks
Example
Escapements
Ratchet Escapements
Slide Escapements
Drum Escapements
Gate Escapements
Jaw Escapements
Parts-Placing Mechanisms
Assembly Robots
Terminology
Advantages of Robot Assembly
Magazines
Types of Magazine Systems
Automatic Feeders for Robot Assembly
Economics of Part Presentation
Design of Robot Assembly Systems
References
Performance and Economics of Assembly Systems
Indexing Machines
Effect of Parts Quality on Downtime
Effects of Parts Quality on Production Time
Effect of Parts Quality on the Cost of Assembly
Free-Transfer Machines
Performance of a Free-Transfer Machine
Average Production Time for a Free-Transfer Machine
Number of Personnel Needed for Fault Correction
Basis for Economic Comparisons of Automation Equipment
Basic Cost Equations
Comparison of Indexing and Free-Transfer Machines
Indexing Machine
Free-Transfer Machine
Effect of Production Volume
Economics of Robot Assembly
Parts Presentation
Profile of Typical Candidate Assembly
Single-Station Systems
Equipment Costs
Personnel Costs
Parts Quality
Basic Cost Equation
Multistation Transfer Systems
Equipment Costs
Cost Equation
References
Design for Manual Assembly
Introduction
Where Design for Assembly Fits in the Design Process
General Design Guidelines for Manual Assembly
Design Guidelines for Part Handling
Design Guidelines for Insertion and Fastening
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
Results of the Analysis
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
Rules for Product Design
Rules for the Design of Parts
Product Design for Robot Assembly
Summary of Design Rules 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
Instructions
PCB Assembly - Equations and Data for Total Operation Cost
Manual
Autoinsertion Machine
Robot Insertion Machine
Glossary of Terms
References
Feasibility Study for Assembly Automation
Machine Design Factors to Reduce Machine Downtime Due to Defective Parts
Feasibility Study
Precedence Diagrams
Manual Assembly of Plug
Quality Levels of Parts
Parts Feeding and Assembly
Special-Purpose Machine Layout and Performance
Indexing Machine
Free-Transfer Machine
Robot Assembly of the Power Plug
References
Problems
Simple Method for the Determination of the Coefficient of Dynamic Friction
The Method
Analysis
Precision of the Method
Discussion
Reference
Out-of-Phase Vibratory Conveyors
Out-of-Phase Conveying
Practical Applications
Reference
Laboratory Experiments
Performance of a Vibratory-Bowl Feeder
Objectives
Equipment
Procedure
Theory
Presentation of Results
Performance of a Horizontal-Delivery Gravity Feed Track
Objectives
Equipment (Objective 1)
Theory (Objective 1)
Procedure (Objective 1)
Results (Objective 1)
Equipment (Objective 2)
Theory (Objective 2)
Procedure (Objective 2)
Results (Objective 2)
Conclusions
Feeding and Orienting Techniques for Small Parts
Coding System
Introduction to the Coding System
Coding Examples
Sample Parts for Practice
Analysis of the Coding of the Sample Parts
Coding System for Small Parts
Feeding and Orienting Techniques
Orienting Devices for Vibratory-Bowl Feeders
Nonvibratory Feeders
Nomenclature
Index
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