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Preface
The Author
Table of Contents
1
Introduction
1.1 Historical Development of the Assembly Process
1.2 Choice of Assembly Method
1.3 Social Effects of Automation
References
2
Automatic Assembly Transfer Systems
2.1 Continuous Transfer
2.2 Intermittent Transfer
2.3 Indexing Mechanisms
2.4 Operator-Paced Free-Transfer Machine
References
3
Automatic Feeding and Orienting - Vibratory Feeders
3.1 Mechanics of Vibratory Conveying
3.2 Effect of Frequency
3.3 Effect of Track Acceleration
3.4 Effect of Vibration Angle
3.5 Effect of Track Angle
3.6 Effect of Coefficient of Friction
3.7 Estimating the Mean Conveying Velocity
3.8 Load Sensitivity
3.9 Solutions to Load Sensitivity
3.10 Spiral Elevators
3.11 Balanced Feeders
3.12 Orientation of Parts
3.13 Typical Orienting System
3.14 Effect of Active Orienting Devices on Feed Rate
3.15 Analysis of Orienting Systems
3.15.1 Orienting System
3.15.2 Method of System Analysis
3.15.3 Optimization
3.16 Performance of an Orienting Device
3.16.1 Analysis
3.17 Natural Resting Aspects of Parts for Automatic Handling
3.17.1 Assumptions
3.17.2 Analysis for Soft Surfaces
3.17.3 Analysis for Hard Surfaces
3.17.4 Analysis for Cylinders and Prisms with Displaced Centers of Mass
3.17.5 Summary of Results
3.18 Analysis of a Typical Orienting System
3.18.1 Design of Orienting Devices
3.19 Out-of-Bowl Tooling
References
4
Automatic Feeding and Orienting - Mechanical Feeders
4.1 Reciprocating-Tube Hopper Feeder
4.1.1 General Features
4.1.2 Specific Applications
4.2 Centerboard Hopper Feeder
4.2.1 Maximum Track Inclination
4.2.2 Load Sensitivity and Efficiency
4.3 Reciprocating-Fork Hopper Feeder
4.4 External Gate Hopper Feeder
4.4.1 Feed Rate
4.4.2 Load Sensitivity and Efficiency
4.5 Rotary-Disk Feeder
4.5.1 Indexing Rotary-Disk Feeder
4.5.2 Rotary-Disk Feeder with Continuous Drive
4.5.3 Load Sensitivity and Efficiency
4.6 Centrifugal Hopper Feeder
4.6.1 Feed Rate
4.6.2 Efficiency
4.7 Stationary-Hook Hopper Feeder
4.7.1 Design of the Hook
4.7.2 Feed Rate
4.8 Bladed-Wheel Hopper Feeder
4.9 Tumbling-Barrel Hopper Feeder
4.9.1 Feed Rate
4.10 Rotary-Centerboard Hopper Feeder
4.11 Magnetic-Disk Feeder
4.12 Elevating Hopper Feeder
4.13 Magnetic Elevating Hopper Feeder
4.14 Magazines
References
5
Feed Tracks, Escapements, Parts- Placement Mechanisms, and Robots
5.1 Gravity Feed Tracks
5.1.1 Analysis of Horizontal-Delivery Feed Track
5.1.2 Example
5.1.3 On/Off Sensors
5.1.3.1 Theory
5.1.4 Feed Track Section
5.1.5 Design of Gravity Feed Tracks for Headed Parts
5.1.5.1 Analysis
5.1.5.2 Results
5.1.5.3 Procedure for Use of Figure 5.17 to Figure 5.20
5.2 Powered Feed Tracks
5.2.1 Example
5.3 Escapements
5.3.1 Ratchet Escapements
5.3.2 Slide Escapements
5.3.3 Drum Escapements
5.3.4 Gate Escapements
5.3.5 Jaw Escapements
5.4 Parts-Placing Mechanisms
5.5 Assembly Robots
5.5.1 Terminology
5.5.2 Advantages of Robot Assembly
5.5.3 Magazines
5.5.4 Types of Magazine Systems
5.5.5 Automatic Feeders for Robot Assembly
5.5.6 Economics of Part Presentation
5.5.7 Design of Robot Assembly Systems
References
6
Performance and Economics of Assembly Systems
6.1 Indexing Machines
6.1.1 Effect of Parts Quality on Downtime
6.1.2 Effects of Parts Quality on Production Time
6.1.3 Effect of Parts Quality on the Cost of Assembly
6.2 Free-Transfer Machines
6.2.1 Performance of a Free-Transfer Machine
6.2.2 Average Production Time for a Free-Transfer Machine
6.2.3 Number of Personnel Needed for Fault Correction
6.3 Basis for Economic Comparisons of Automation Equipment
6.3.1 Basic Cost Equations
6.4 Comparison of Indexing and Free- Transfer Machines
6.4.1 Indexing Machine
6.4.2 Free-Transfer Machine
6.4.3 Effect of Production Volume
6.5 Economics of Robot Assembly
6.5.1 Parts Presentation
6.5.2 Profile of Typical Candidate Assembly
6.5.3 Single-Station Systems
6.5.3.1 Equipment Costs
6.5.3.2 Personnel Costs
6.5.3.3 Parts Quality
6.5.3.4 Basic Cost Equation
6.5.4 Multistation Transfer Systems
6.5.4.1 Equipment Costs
6.5.4.2 Cost Equation
References
7
Design for Manual Assembly
7.1 Introduction
7.2 Where Design for Assembly Fits in the Design Process
7.3 General Design Guidelines for Manual Assembly
7.3.1 Design Guidelines for Part Handling
7.3.2 Design Guidelines for Insertion and Fastening
7.4 Development of a Systematic DFA Analysis Method
7.5 DFA Index
7.6 Classification System for Manual Handling
7.7 Classification System for Manual Insertion and Fastening
7.8 Effect of Part Symmetry on Handling Time
7.9 Effect of Part Thickness and Size on Handling Time
7.10 Effect of Weight on Handling Time
7.11 Parts Requiring Two Hands for Manipulation
7.12 Effects of Combinations of Factors
7.13 Threaded Fasteners
7.14 Effects of Holding Down
7.15 Problems with Manual Assembly Time Standards
7.16 Application of the DFA Method
7.16.1 Results of the Analysis
7.17 Further General Design Guidelines
References
8
Product Design for High-Speed Automatic Assembly and Robot Assembly
8.1 Introduction
8.2 Design of Parts for High-Speed Feeding and Orienting
8.3 Example
8.4 Additional Feeding Difficulties
8.5 High-Speed Automatic Insertion
8.6 Example
8.7 Analysis of an Assembly
8.8 General Rules for Product Design for Automation
8.9 Design of Parts for Feeding and Orienting
8.10 Summary of Design Rules for High- Speed Automatic Assembly
8.10.1 Rules for Product Design
8.10.2 Rules for the Design of Parts
8.11 Product Design for Robot Assembly
8.11.1 Summary of Design Rules for Robot Assembly
References
9
Printed-Circuit-Board Assembly
9.1 Introduction
9.2 Terminology
9.3 Assembly Process for PCBs
9.4 SMD Technology
9.5 Estimation of PCB Assembly Costs
9.6 Worksheet and Database for PCB Assembly Cost Analysis
9.6.1 Instructions
9.7 PCB Assembly - Equations and Data for Total Operation Cost
9.7.1 Manual
9.7.2 Autoinsertion Machine
9.7.3 Robot Insertion Machine
9.8 Glossary of Terms
References
10
Feasibility Study for Assembly Automation
10.1 Machine Design Factors to Reduce Machine Downtime Due to Defective Parts
10.2 Feasibility Study
10.2.1 Precedence Diagrams
10.2.2 Manual Assembly of Plug
10.2.3 Quality Levels of Parts
10.2.4 Parts Feeding and Assembly
10.2.5 Special-Purpose Machine Layout and Performance
10.2.5.1 Indexing Machine
10.2.5.2 Free-Transfer Machine
10.2.6 Robot Assembly of the Power Plug
References
Problems
Appendix A Simple Method for the Determination of the Coefficient of Dynamic Friction
A.1 The Method
A.2 Analysis
A.3 Precision of the Method
A.4 Discussion
Reference
Appendix B Out-of-Phase Vibratory Conveyors
B.1 Out-of-Phase Conveying
B.2 Practical Applications
Reference
Appendix C
C.1 Performance of a Vibratory-Bowl Feeder
C.1.1 Objectives
C.1.2 Equipment
C.1.3 Procedure
C.1.4 Theory
C.1.5 Presentation of Results
C.2 Performance of a Horizontal-Delivery Gravity Feed Track
C.2.1 Objectives
C.2.2 Equipment (Objective 1)
C.2.3 Theory (Objective 1)
C.2.4 Procedure (Objective 1)
C.2.5 Results (Objective 1)
C.2.6 Equipment (Objective 2)
C.2.7 Theory (Objective 2)
C.2.8 Procedure (Objective 2)
C.2.9 Results (Objective 2)
C.2.10 Conclusions
Appendix D
D.1 Coding System
D.1.1 Introduction to the Coding System
Envelope
Features
Rotational Symmetry
Surfaces and Views of Rotational, Triangular, or Square Parts
D.1.2 Coding Examples
Example 1
Example 2
Example 3
Example 4
D.1.3 Sample Parts for Practice
D.1.4 Analysis of the Coding of the Sample Parts
Example 1: Code No. 600
Example 2: Code No. 074
Example 3: Code No. 220
Example 4: Code No. 354
Example 5: Code No. 578
Example 6: Code No. 685
Example 7: Code No. 853
Example 8: Code No. 904
D.1.5 Coding System for Small Parts
Small Parts for Automatic Handling (Choice of the first digit)
Rotational Parts (Parts with a first digit of 0, 1, or 2)
Triangular and Square Parts (Parts with a first digit of 3, 4, or 5)
Triangular and Square Parts (Parts with a first digit of 3, 4, or 5)
Triangular and Square Parts (Parts with a first digit of 3, 4, or 5) (continued)
Rectangular Parts (Parts with a first digit of 6, 7, or 8)
Rectangular Parts (Parts with a first digit of 6, 7, or 8)
Difficult-to-Feed Parts (parts with a first digit of 9)
Difficult-to-Feed Parts (parts with a first digit of 9)
D.2 Feeding and Orienting Techniques
D.3 Orienting Devices for Vibratory-Bowl Feeders
D.4 Nonvibratory Feeders
Nomenclature
Index
A
C
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
Nội dung
[...]... reduction in assembly costs and, for medium production volumes, robot assembly would give a 61% reduction However, with the most efficient design consisting of only two parts, design for assembly (DFA) gives a 92% reduction in manual assembly costs and, for this design, the further benefits obtained through automation are negligible 14 AssemblyAutomation and ProductDesign 48 mm 1 Annual production volumes:... Analysis of an Assembly .271 General Rules for ProductDesign for Automation 272 Design of Parts for Feeding and Orienting 276 Summary of Design Rules for High-Speed Automatic Assembly 280 8.10.1 Rules for ProductDesign 280 8.10.2 Rules for the Design of Parts 280 8.11 ProductDesign for Robot Assembly 281 8.11.1 Summary of Design Rules for Robot Assembly 287... effects of product design, it can be stated that improvements in productdesign leading to greater economy in the manufacture of parts and the assembly of products will always result in improvements in both labor and total productivity To design a product for ease of assembly requires no expenditure on capital equipment, and yet the significant reductions in assembly times have a marked effect on productivity... productivity In fact, the design of products for ease of assembly has much greater potential for reducing costs and improving productivity than assemblyautomation [10] This is illustrated by the example shown in Figure 1.3 This graph shows clearly that automation becomes less attractive as the productdesign is improved For the original design manufactured in large volumes, high-speed assemblyautomation would... product In some situations, assembly by manual workers would be hazardous because of high temperatures and the presence of toxic or even explosive substances Under these circumstances, productivity and cost considerations become less important 10 AssemblyAutomation and ProductDesign 1.3 SOCIAL EFFECTS OF AUTOMATION Much has been said and written regarding the impact of automationand robots in industry... the insertion of nonstandard (odd-form) electronic components that cannot be handled by the available automatic-insertion machines 6 AssemblyAutomation and ProductDesign For many years, manufacturers of electrical and electronic products have spent more on assembly technology than on any other industry [3] 1.2 CHOICE OF ASSEMBLY METHOD When considering the manufacture of a product, a company must... choice of assembly method For a new product, the following considerations are generally important: 1 2 3 4 Suitability of the productdesign Production rate required Availability of labor Market life of the product If the product has not been designed with automatic assembly in mind, manual assembly is probably the only possibility Similarly, automation will not be practical unless the anticipated production... Equation .216 References 217 Chapter 7 7.1 7.2 7.3 Design for Manual Assembly 219 Introduction 219 Where Design for Assembly Fits in the Design Process .219 General Design Guidelines for Manual Assembly 221 7.3.1 Design Guidelines for Part Handling 221 7.3.2 Design Guidelines for Insertion and Fastening 222 7.4 Development of a Systematic DFA Analysis Method... of assembly machines are presented, and the overall performance of assembly systems is discussed Finally, detailed analyses of the suitability of parts and products for both manual and automatic assembly are presented REFERENCES 1 Schwartz, W.H., An Assembly Hall of Fame, Assembly Engineering, January 1988 2 Nof, S.Y (Ed.), Handbook of Industrial Robots, 2nd ed., John Wiley & Sons, New York, 1999 3 Assembly. .. Manual Assembly Time Standards .242 7.16 Application of the DFA Method .244 7.16.1 Results of the Analysis 248 7.17 Further General Design Guidelines 251 References 254 Chapter 8 ProductDesign for High-Speed Automatic Assemblyand Robot Assembly 257 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 Introduction 257 Design of Parts for High-Speed Feeding and . Ginzburg
and Robert Ballas
58. Product Design for Manufacture and Assembly:
Second Edition, Revised and Expanded,
Geoffrey Boothroyd,
Peter Dewhurst, and. Edition, Revised and Expanded,
John P. Tanner
37. Assembly Automation and Product Design,
Geoffrey Boothroyd
38. Hybrid Assemblies and Multichip Modules,