Jegadeesan A.J.,Lucas TVS |
Karunamoorthy L.,Anna University
Journal of Mechanical Science and Technology | Year: 2015
Hot staking is the preferred process for conductor-commutator joints in the DC motor armatures as it is versatile and cost effective. But however its application is limited by the peak failure load of the joint which depends only on the mechanical contact as there is no amalgamation or diffusion of metals in the faying surface. This study investigates the mechanical joint strength and found its variation has a positional pattern which is significantly related to similar pattern in electrode heat. A hypothesis for the similarity is reasoned and validated, which enabled evolution of a feasible solution to have differential input of energy compensating the variation in heat. This resulted in overcoming the limitation of joint strength in introduction of hot staked armatures to new applications. The use of Shainin clue generating tool, Relations diagram and visualizing the physical mechanism complemented the problem solving approach in causal clue exploration, hypothesis reasoning and solution development. © 2015, The Korean Society of Mechanical Engineers and Springer-Verlag Berlin Heidelberg.
Jegadheeson A.J.,Lucas TVS |
Karunamoorthy L.,Anna University |
Arunkumar N.,St. Joseph's College |
Balaji A.,Lucas TVS |
Rajkamal M.,Lucas TVS
Journal of Advanced Manufacturing Systems | Year: 2012
Evolution is "understanding and overcoming current constraints in small steps toward optimum." "Understanding" requires elucidation of facts and corroborating theories that can explain those facts in a coherent manner. "Overcoming" requires self-development to suit the environment. In this paper, a case study about how a manufacturing process is improved in terms of productivity and quality using evolutionary improvements is explained. Here "Understanding" is achieved through use of Shainin Technique, PM analysis, Affinity Diagram, and the engineer's ingenuity, along with Relations diagram. "Overcoming" is achieved through Geometrical Analysis and Designed Experiments. The Study has set a new benchmark in the Stator riveting process by proving it can yield the desired results, and the need to adapt welding process is avoided. © 2012 World Scientific Publishing Company.