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Camillo J.,ASSEMBLY
Assembly | Year: 2014

One of the most important responsibilities at a wire harness shop is that of matchmaker who is the person responsible for pairing the right blade with each wire so it is properly stripped or cut. In small shops, this duty often falls on the machine operator or even the owner. Large harness manufacturers, in contrast, might have machine-setup specialists whose job includes selecting, monitoring and replacing blades. Regardless of facility size and production level, it is imperative that the proper blade is chosen for each wire. Two factors account for the popularity of V blades: their versatility and variation. Standard blades feature a 90-degree V configuration that provides good quality stripping and cutting of a wide range of wire sizes (26 to 10 AWG) and insulation types (PVC, Teflon, fiberglass). V blades are used in sets (top and bottom) that bypass each other to cut wire. Stripping V blades penetrate the insulation at four points that, when connected, form a diamond.


Camillo J.,ASSEMBLY
Assembly | Year: 2014

Dublin, VA, is well known for being named after Ireland's most famous city. But it is best known as home to the largest Volvo Trucks manufacturing facility in the world. Located on nearly 300 acres, this facility houses a welding and painting plant, and an assembly plant under one roof. Its nearly 2,000 workers assemble thousands of Class 8 trucks annually. Energy efficiency has been a priority at the plant for several years. In December 2009, the company joined the Department of Energy's Save Energy Now LEADER initiative. This federal program calls on manufacturers to reduce their facilities' energy intensity by 25 percent over a 10-year time frame. Although the welding operation consistently produced high-quality welds, it also generated a significant amount of oily smoke and fumes. For many years, Volvo had relied on traditional hoods and oversized fans to collect, filter and exhaust air through ductwork to the outside. Unfortunately, this setup did not meet the latest EPA air quality standards or Volvo's energy- usage goals.


Camillo J.,Assembly
Assembly | Year: 2014

An epiphany is often defined as the moment when someone more clearly understands a problem or situation, or sees it from a different perspective. In the context of assembly, the term might refer to when an inventor or engineer has the idea for a new or better product or process. By early 2013, Graco formed a new-product engineering team to transform its original feeder design into a commercially viable product. Over several months, the feeder's table and its surface geometry were redesigned and optimized. Advanced vibration dampening features were added, and operator controls were incorporated in the unit base. In October 2013, the G-Flex 1500 feeder was brought to market. It was showcased at the inaugural ASSEMBLY Show later that month. The purpose of any flexible feeder is to present parts to a vision-guided robot. One or more cameras take images of the parts, and vision software indicates which parts the robot needs to retrieve and move.


Camillo J.,Assembly
Assembly | Year: 2014

Optimizing product quality is an ongoing challenge for all employees of Robert Bosch GmbH, the world's largest supplier of automotive components. To achieve its goal, the company often turns to PA-AMTO, an in-house provider of assembly systems and specialized equipment. PA-ATMO's responsibilities include testing leak-detection procedures and developing leak-testing systems for several company divisions. One division is gasoline services, which manufactures specialized gas injection and engine control systems in Bamberg, Germany. PA-ATMO developed a test system for the bifuel valves that has four parallel stations. Each station features a TGuard leak sensor and a vacuum chamber with a volume of 1 liter. The new system takes up less floor space and offers higher productivity than the conventional detector. It tests up to four valves simultaneously, whereas the old system only tested one.


Sprovieri J.,Assembly
Assembly | Year: 2014

Viking Plastics of Corry, PA, is a global supplier of engineered, injection-molded and assembled sealing components to many industries. Its products include plastic connectors, closures, clips, brackets, caps and fasteners. The eight-station system, which was built by Automated Industrial Systems Inc. in Erie, PA, employs a camdriven rotary indexing table with double-nest fixtures at each station. A stainless steel vibratory feeder bowl with a bulk hopper supplies two feed lines for the caps. At the first processing station, a pick-and-place device transfers two caps to a fixture on the dial. A signal alerts the operator to remove the full container and replace it with an empty one. Station 8 is used as a reject station for bad product. All parts and debris removed here are delivered to a remote location to prevent the possibility of getting mixed with good parts. The entire system is mounted on a fabricated steel frame. It is controlled by an Allen-Bradley MicroLogix 1500 PLC with a PanelView Plus 600 operator interface touch screen control panel.


Camillo J.,Assembly
Assembly | Year: 2014

Great advances have been made in computational fluid dynamics and flight-simulation programs. The tunnels enable aerospace manufacturers to conduct a wide range of tests, including stability and control, jet effects and captive trajectory. More importantly, the tunnels eliminate the need for full-size prototypes, which take years to develop and build, and cost millions of dollars. Three video cameras are used for standing air-flow testing. Another is required for the schlieren test, which captures the flow away from an object's surface. A fifth video camera, along with a still-image-camera, is required for oil-flow visualization. For several years, Calspan engineers used five standard-definition video cameras and a Hasselblad still filmbased camera under fluorescent lighting. Engineers streamed video through a frame rate and signal converter, and used a matrix switcher for display and recording. Wind-tunnel data was overlaid and recorded by a PC with a video capture card.


Engineers at Ford Motor Co. are welcoming this challenge in a software pilot program being implemented at the company's Wayne, MI, assembly plant. The software is called IntoSite. Developed by Siemens PLM, it uses Google Earth infrastructure that enables Ford to virtually navigate any of its 65 assembly plants worldwide. Equally important, the software increases global collaboration so workers can share best practices, resolve inconsistencies and improve efficiency and standardization. IntoSite is a cloud-based Web application that provides a virtual 3D image of the plant's interior. Engineers and other team members use the software to better understand and optimize what assemblers do at specific workstations and the design of complete assembly lines. At any virtual location in the plant, the person can add pins and upload videos, documents and images to these pins. Documents pertaining to specific issues are stored and accessed in a common place rather than multiple internal systems.


F&P America Manufacturing Inc. has continued to operate at maximum capacity due to JIT manufacturing and safe robotic welding. The company opened in Troy, OH, in 1994 as a 100,000-square-foot welding shop with 80 employees. Today, the company operates a 300,000-square-foot facility where 500 employees stamp, weld, assemble and paint 1,800 to 2,000 assemblies per day, six days a week. More than 300 robotic welders are required for the plant's high productivity. But, worker safety is F&P's main priority, as it has achieved 1 million hours without a lost time accident on several occasions. To protect workers, the company places physical barriers between them and the robots, and uses Guardian automated light curtains in 12 robotic weld cells. Frommelt Safety Products makes the curtains, which shield workers from welding arc flash and splatter, and prevent their entry into the welding cell. The light curtains include several dual-units and two 13-foot-wide units. All models feature curtains made of fire-resistant, 50-ounce black vinyl.


Camillo J.,Assembly
Assembly | Year: 2014

Pencil-shaped, the Bloodhound SSC supersonic car aims to rewrite history in the summer of 2015. At that time, the car will attempt to reach a land speed of 1,000 mph. It will easily exceed the world land speed record of 763 mph, set by its predecessor Thrust SSC on October 15, 1997. The Bloodhound is designed by professors Oubay Hassan and Ken Morgan of the college of engineering at Swansea (Wales University) and has been in development since 2008. A full-scale model of the car was unveiled in July 2010 at the Farnborough International Airshow in Hampshire, England. The car is powered by a Eurojet EJ200 engine, a hybrid rocket and a 750-hp petrol engine auxiliary power unit. The jet engine brings the car up to 300 mph, whereupon the rocket boosts speed to 1,000 mph. Total ramp up time is 42 seconds. The petrol engine drives the rocket's oxidizer pump. Andy Green, an RAF pilot, drives the Bloodhound lying down in a feet-first position.


Camillo J.,ASSEMBLY
Assembly | Year: 2014

There are a wide variety of screws for specialized tasks and specific fastening problems. The Mortorq drive series by Phillips Screw Co. consists of the Mortorq spiral drive, Mortorq Super enhanced spiral drive and External Mortorq Super for bolts. Mortorq was developed to provide aerospace manufacturers a drive head that ensured removal of all screws during plane repairs and overhauls. The Mortorq and Mortorq Super drives feature four curved, triangular wings spread from a center point. This shape provides full contact of the driver bit. Its low-profile head reduces the weight of fastened components, and its shallow recess enables off-angle driving and accommodates paint build-up. REMINC's Taptite W, Taptite II and Taptite 2000 screws feature a trilobular thread body that has a triangular cross-section rather than a circular one. The trilobular shape produces high-stripping torque with limited friction during thread forming.

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