The evolution of assembly processes is intertwined with the evolution of mass-production techniques. Engineers have been looking for and developing new methods of manufacture or production as the demand for finished goods in huge quantities has grown, particularly in the armaments industry. The assembly process is necessary when two or more component pieces must be secured together, and it is one of the more critical manufacturing processes. Techniques known as Design For Assembly, DFA, have been used since the early eighties. Most DFA methods are focused on product evaluation. There is, naturally, a need to evaluate products, but few DFA methods provide the user with information on how to design the product to avoid assembly problems. As the level of competition rises, lead times shorten and production processes become more complex. Companies can no longer afford to approach design and manufacturing in a haphazard manner.
This book provides extensive details about the vast topic to assembly automation and product design. It deals with the study of assembly transfer system, automatic feeding, mechanical feeders, and placement mechanisms. This book is an epitome of knowledge related to the enhancement of knowledge and skill. It also focuses on design for manual assembly, product design for high-speed automatic assembly, and printed-circuit-board assembly. This book is a valuable compilation of various topics, ranging from the most basic to the most complex ones. For those who have an interest in assembly automation and product design, this book will prove to be a valuable source of knowledge.
Preface
1. Introduction
1. Introduction
2. Historical Development of the Assembly Process
3. Choice of Assembly Method
4. Social Effects of Automation
Conclusion
References
2. Automatic Assembly Transfer System
1. Introduction
2. Continuous Transfer
3. Intermittent Transfer
4. Indexing Mechanisms
5. Operator-Paced Free-Transfer Machine
Conclusion
References
3. Automatic Feeding and Orienting - Vibratory Feeders
1. Introduction
2. Mechanics of Vibratory Conveying
3. Effect of Frequency
4. Effect of Track Acceleration
5. Effect of Coefficient of Friction
6. Load Sensitivity
7. Spiral Elevators
8. Balanced Feeders
9. Orientation of Parts
10. Orienting System
11. Optimization
12. Performance of an Orienting Device
13. Natural Resting Aspects of Parts for Automatic Handling
14. Analysis of a Typical Orienting System
15. Design of Orienting Devices
16. Out-of-Bowl Tooling
Conclusion
References
4. Automatic Feeding and Orienting - Mechanical Feeders
1. Introduction
2. Reciprocating-Tube Hopper Feeder
3. Centerboard Hopper Feeder
4. Reciprocating-Fork Hopper Feeder
5. Rotary-Disk Feeder
6. Centrifugal Hopper Feeder
7. Stationary-Hook Hopper Feeder
8. Bladed-Wheel Hopper Feeder
9. Tumbling-Barrel Hopper Feeder
10. Rotary-Centerboard Hopper Feeder
11. Magnetic-Disk Feeder
12. Elevating Hopper Feeder
13. Magnetic Elevating Hopper Feeder
14. Magazines
Conclusion
References
5. Feed Tracks, Escapements, Parts - Placement Mechanisms, & Robots
1. Introduction
2. Gravity Feed Tracks
3. Powered Feed Tracks
4. Escapements
5. Parts-Placing Mechanisms
6. Assembly Robots
7. Robot Applications in Automotive Manufacturing
Conclusion
References
6. Performance and Economics of Assembly Systems
1. Introduction
2. Indexing Machines
3. Free-Transfer Machines
4. Economics of Robot Assembly
Conclusion
References
7. Design for Manual Assembly
1. Introduction
2. Where Design for Assembly Fits in the Design Process
3. Development of a Systematic DFA Analysis Method
4. DFA Index
5. Classification System for Manual Handling
6. Effect of Part Thickness and Size on Handling Time
7. Threaded Fasteners
8. Problems with Manual Assembly Time Standards
9. Application of the DEA Method
Conclusion
References
8. Product Design for High-Speed Automatic Assembly and
Robot Assembly
1. Introduction
2. Design of Parts for High-Speed Feeding and Orienting
3. Additional Feeding Difficulties
4. High-Speed Automatic Insertion
5. Analysis of an Assembly
6. General Rules for Product Design for Automation
7. Design of Parts for Feeding and Orienting
8. Summary of Design Rules for High-Speed Automatic Assembly
9. Rules for the Design of Parts
Conclusion
References
9. Printed-Circuit-Board Assembly
1. Introduction
2. Terminology
3. Assembly Process for PCBs
4. SMD Technology
5. Estimation of PCB Assembly Costs
6. PCB Assembly - Equations and Data for Total Operation Cost
Conclusion
References
10. Feasibility Study for Assembly Automation
1. Introduction
2. Machine Design Factors to Reduce Machine Downtime Due to Defective Parts
3. Feasibility Study
Conclusion
References
Index
Zelda Fountain has served as a Visiting Professor at various universities across America & Europe. She holds Ph.D. in Industrial Engineering from State University, Boise. Her research interests are in assembling machines, assembly-line methods, machine automation and production planning. She is also a senior member of several technical & scientific societies. Fountain has organized many international conferences and has authored and edited a number of articles, research papers and book chapters in the field of manufacturing engineering, product design and quality control.
