Abstract: This paper reports on the performance of deliberately unbalanced, reliable, non-automated and assembly lines that merge, whose workstations differ in terms of their mean operation times. Simulations are carried out on 5- and 8-station lines with 1, 2 and 4 buffer capacity units, % degrees of line imbalance of 2, 5 and 12, and 24 different patterns of means imbalance. Data on two performance measures, namely throughput and average buffer level were gathered, statistically analysed and compared to a merging balanced line counterpart. It was found that the best configurations are a balanced line arrangement and a monotone decreasing order for each of the parallel merging lines, with the first generally resulting in a lower throughput and the second leading to a lower average buffer level than those of a balanced line.
Abstract: There is a gap at combustor-turbine interface where leakage flow comes out to prevent hot gas ingestion into the gas turbine nozzle platform. The leakage flow protects the nozzle endwall surface from the hot gas coming from combustor exit. For controlling flow’s stream, the gap’s geometry is transformed by changing fillet radius size. During the operation, step configuration is occurred that was unintended between combustor-turbine platform interface caused by thermal expansion or mismatched assembly. In this study, CFD simulations were performed to investigate the effect of the fillet and step on heat transfer and film cooling effectiveness on the nozzle platform. The Reynolds-averaged Navier-stokes equation was solved with turbulence model, SST k-omega. With the fillet configuration, predicted film cooling effectiveness results indicated that fillet radius size influences to enhance film cooling effectiveness. Predicted film cooling effectiveness results at forward facing step configuration indicated that step height influences to enhance film cooling effectiveness. We suggested that designer change a combustor-turbine interface configuration which was varied by fillet radius size near endwall gap when there was a step at combustor-turbine interface. Gap shape was modified by increasing fillet radius size near nozzle endwall. Also, fillet radius and step height were interacted with the film cooling effectiveness and heat transfer on endwall surface.
Abstract: Accurate prediction of the cooling/heating load and consequently, the sizing of the heating, ventilating, and air-conditioning equipment require precise calculation of the heat transfer mainly by conduction through envelope components of a building. The thermal resistance of most thermal insulation materials depends on the operating temperature. The temperature to which the insulation materials are exposed varies, depending on the thermal resistance of the materials, the location of the insulation layer within the assembly system, and the effective temperature which depends on the amount of solar radiation received on the surface of the assembly. The main objective of this paper is to investigate the change of the thermal conductivity of polystyrene insulation material in terms of the temperature at the mid-thickness of the material and its effect on the cooling load required by the building.
Abstract: Background: The 2004 World Health Assembly called for specific actions to halt the overweight and obesity epidemic that is currently penetrating urban populations in the developing world. Adolescents require particular attention due to their vulnerability to develop obesity and the fact that adolescent weight tracks strongly into adulthood. However, there is scarcity of information on the modifiable risk factors to be targeted for primary intervention among urban adolescents in Ethiopia. This study was aimed at determining the magnitude and risk factors of overweight and obesity among high school adolescents in Addis Ababa. Methods: An institution-based cross-sectional study was conducted in February and March 2014 on 456 randomly selected adolescents from 20 high schools in Addis Ababa city. Demographic data and other risk factors of overweight and obesity were collected using self-administered structured questionnaire, whereas anthropometric measurements of weight and height were taken using calibrated equipment and standardized techniques. The WHO STEPS instrument for chronic disease risk was applied to assess dietary habit and physical activity. Overweight and obesity status was determined based on BMI-for-age percentiles of WHO 2007 reference population. Results: The prevalence rates of overweight, obesity, and overall overweight/ obesity among high school adolescents in Addis Ababa were 9.7% (95%CI = 6.9-12.4%), 4.2% (95%CI = 2.3-6.0%), and 13.9% (95%CI = 10.6-17.1%), respectively. Overweight/obesity prevalence was highest among female adolescents, in private schools, and in the higher wealth category. In multivariable regression model, being female [AOR(95%CI) = 5.4(2.5,12.1)], being from private school [AOR(95%CI) = 3.0(1.4,6.2)], having >3 regular meals [AOR(95%CI) = 4.0(1.3,13.0)], consumption of sweet foods [AOR(95%CI) = 5.0(2.4,10.3)] and spending >3 hours/day sitting [AOR(95%CI) = 3.5(1.7,7.2)] were found to increase overweight/ obesity risk, whereas high Total Physical Activity level [AOR(95%CI) = 0.21(0.08,0.57)] and better nutrition knowledge [AOR(95%CI) = 0.160.07,0.37)] were found protective. Conclusions: More than one in ten of the high school adolescents were affected by overweight/obesity with dietary habit and physical activity are important modifiable risk factors. Well-tailored nutrition education program targeting lifestyle change should be initiated with more emphasis to female adolescents and students in private schools.
Abstract: Integrated systems for product design, manufacturing, and lifecycle management are difficult to implement and customize. Commercial software vendors, including CAD/CAM and third party PDM/PLM developers, create user interfaces and functionality that allow their products to be applied across many industries. The result is that systems become overloaded with functionality, difficult to navigate, and use terminology that is unfamiliar to engineers and production personnel. For example, manufacturers of automotive, aeronautical, electronics, and household products use similar but distinct methods and processes. Furthermore, each company tends to have their own preferred tools and programs for controlling work and information flow and that connect design, planning, and manufacturing processes to business applications. This paper presents a methodology and a case study that addresses these issues and suggests that in the future more companies will develop personalized applications that fit to the natural way that their business operates. A functioning system has been implemented at a highly competitive U.S. aerospace tooling and component supplier that works with many prominent airline manufacturers around the world including The Boeing Company, Airbus, Embraer, and Bombardier Aerospace. During the last three years, the program has produced significant benefits such as the automatic creation and management of component and assembly designs (parametric models and drawings), the extensive use of lightweight 3D data, and changes to the way projects are executed from beginning to end. CATIA (CAD/CAE/CAM) and a variety of programs developed in C#, VB.Net, HTML, and SQL make up the current system. The web-based platform is facilitating collaborative work across multiple sites around the world and improving communications with customers and suppliers. This work demonstrates that the creative use of Application Programming Interface (API) utilities, libraries, and methods is a key to automating many time-consuming tasks and linking applications together.
Abstract: In the last decades, an increasing set of companies adopted lean philosophy to improve their productivity and efficiency promoting the so-called continuous improvement concept, reducing waste of time and cutting off no-value added activities. In parallel, increasing attention rises toward green practice and management through the spread of the green supply chain pattern, to minimise landfilled waste, drained wastewater and pollutant emissions. Starting from a review on contributions deepening lean and green principles applied to supply chain management, the most relevant drivers to measure the performance of industrial processes are pointed out. Specific attention is paid on the role of cost because it is of key importance and it crosses both lean and green principles. This analysis leads to figure out an original reference framework for integrating lean and green principles in designing and managing supply chains. The proposed framework supports the application, to the whole value chain or to parts of it, e.g. distribution network, assembly system, job-shop, storage system etc., of the lean-green integrated perspective. Evidences show that the combination of the lean and green practices lead to great results, higher than the sum of the performances from their separate application. Lean thinking has beneficial effects on green practices and, at the same time, methods allowing environmental savings generate positive effects on time reduction and process quality increase.
Abstract: Due to the higher power loss levels in electronic components, the thermal design of PCBs (Printed Circuit Boards) of an assembled device becomes one of the most important quality factors in electronics. Nonetheless, some of leading causes of the microelectronic component failures are due to higher temperatures, the leakages or thermal-mechanical stress, which is a concern, is the reliability of microelectronic packages. This article presents an experimental approach to measure the junction temperature of exposed pad packages. The implemented solution is in a prototype phase, using a temperature-sensitive parameter (TSP) to measure temperature directly on the die, validating the numeric results provided by the Mechanical APDL (Ansys Parametric Design Language) under same conditions. The physical device-under-test is composed by a Thermal Test Chip (TTC-1002) and assembly in a QFN cavity, soldered to a test-board according to JEDEC Standards. Monitoring the voltage drop across a forward-biased diode, is an indirectly method but accurate to obtain the junction temperature of QFN component with an applied power range between 0,3W to 1.5W. The temperature distributions on the PCB test-board and QFN cavity surface were monitored by an infra-red thermal camera (Goby-384) controlled and images processed by the Xeneth software. The article provides a set-up to monitorize in real-time the junction temperature of ICs, namely devices with the exposed pad package (i.e. QFN). Presenting the PCB layout parameters that the designer should use to improve thermal performance, and evaluate the impact of voids in solder interface in the device junction temperature.
Abstract: The main purpose of this article is to provide a comprehensive review of various physical and chemical processes for electronic waste (e-waste) recycling, their advantages and shortfalls towards achieving a cleaner process of waste utilization, with especial attention towards extraction of metallic values. Current status and future perspectives of waste printed circuit boards (PCBs) recycling are described. E-waste characterization, dismantling/ disassembly methods, liberation and classification processes, composition determination techniques are covered. Manual selective dismantling and metal-nonmetal liberation at – 150 µm at two step crushing are found to be the best. After size reduction, mainly physical separation/concentration processes employing gravity, electrostatic, magnetic separators, froth floatation etc., which are commonly used in mineral processing, have been critically reviewed here for separation of metals and non-metals, along with useful utilizations of the non-metallic materials. The recovery of metals from e-waste material after physical separation through pyrometallurgical, hydrometallurgical or biohydrometallurgical routes is also discussed along with purification and refining and some suitable flowsheets are also given. It seems that hydrometallurgical route will be a key player in the base and precious metals recoveries from e-waste. E-waste recycling will be a very important sector in the near future from economic and environmental perspectives.
Abstract: Problems exist in the present construction industry in China. Conflicts hinder the development of the whole society, such as contradictions between resource reservation and a huge population, living space needs and low building production efficiency, as well as environment protection and high pollution production pattern. In order to solve the problems and find a solution, research is needed to explore a building system. By investigating the whole architectural process and contrasting analysis of light structures and heavy structures, the paper raised the concepts to cope with the existing challenges, such as design conception based on product and real construction processes, design methods focusing on components, and maximum utilization of the temporary building by optimizing the construction speed and building performance. The project was not only designed in virtual reality, but was also physically constructed in the real world. A series of aluminum light structure housing systems were dictated at last, with the characteristics of high performance, extremely rapid construction speed and also flexible function. It can be used in lots of aspects ranging from a single building in a remote area to a large residential community.
Abstract: In the aviation industry, many faults may occur frequently during the maintenance processes and assembly operations of complex structured aircrafts because of their high dependencies of components. These faults affect the quality of aircraft parts or developed modules adversely. Technical employee requires long time and high labor force while checking the correctness of each component. In addition, the person must be trained regularly because of the ever-growing and changing technology. Generally, the cost of this training is very high. Augmented Reality (AR) technology reduces the cost of training radically and improves the effectiveness of the training. In this study, the usage of AR technology in the aviation industry has been investigated and the effectiveness of AR with heads-up display glasses has been examined. An application has been developed for comparison of production process with AR and manual one.
Abstract: For several hundred years, the design of railway tracks
has practically remained unchanged. Traditionally, rail tracks are
placed on a ballast layer due to several reasons, including economy,
rapid drainage, and high load bearing capacity. The primary function
of ballast is to distributing dynamic track loads to sub-ballast and
subgrade layers, while also providing lateral resistance and allowing
for rapid drainage. Upon repeated trainloads, the ballast becomes
fouled due to ballast degradation and the intrusion of fines which
adversely affects the strength and deformation behaviour of ballast.
This paper presents the use of three-dimensional discrete element
method (DEM) in studying the shear behaviour of the fouled ballast
subjected to direct shear loading. Irregularly shaped particles of
ballast were modelled by grouping many spherical balls together in
appropriate sizes to simulate representative ballast aggregates. Fouled
ballast was modelled by injecting a specified number of miniature
spherical particles into the void spaces. The DEM simulation
highlights that the peak shear stress of the ballast assembly decreases
and the dilation of fouled ballast increases with an increase level of
fouling. Additionally, the distributions of contact force chain and
particle displacement vectors were captured during shearing progress,
explaining the formation of shear band and the evolutions of
volumetric change of fouled ballast.
Abstract: Manufacturing process has been considered as one of
the most important activity in business process. It correlates with
productivity and quality of the product so industries could fulfill
customer’s demand. With the increasing demand from customer,
industries must improve their manufacturing ability such as shorten
lead-time and reduce wastes on their process. Lean manufacturing
has been considered as one of the tools to waste elimination in
manufacturing or service industry. Workforce development is one
practice in lean manufacturing that can reduce waste generated from
operator such as waste of unnecessary motion. Anthropometric
approach is proposed to determine the recommended measurement in
operator’s work area. The method will get some dimensions from
Indonesia people that related to piston workstation. The result from
this research can be obtained new design for the work area
considering ergonomic aspect.
Abstract: The change of conditions for production companies in
high-wage countries is characterized by the globalization of
competition and the transition of a supplier´s to a buyer´s market. The
companies need to face the challenges of reacting flexibly to these
changes. Due to the significant and increasing degree of automation,
assembly has become the most expensive production process.
Regarding the reduction of production cost, assembly consequently
offers a considerable rationalizing potential. Therefore, an
aerodynamic feeding system has been developed at the Institute of
Production Systems and Logistics (IFA), Leibniz Universitaet
Hannover. This system has been enabled to adjust itself by using a
genetic algorithm. The longer this genetic algorithm is executed the
better is the feeding quality. In this paper, the relation between the
system´s setting time and the feeding quality is observed and a
function which enables the user to achieve the minimum of the total
feeding time is presented.
Abstract: Considering the challenges of short product life cycles
and growing variant diversity, cost minimization and manufacturing
flexibility increasingly gain importance to maintain a competitive
edge in today’s global and dynamic markets. In this context, an
aerodynamic part feeding system for high-speed industrial assembly
applications has been developed at the Institute of Production
Systems and Logistics (IFA), Leibniz Universitaet Hannover. The
aerodynamic part feeding system outperforms conventional systems
with respect to its process safety, reliability, and operating speed. In
this paper, a multi-objective optimisation of the aerodynamic feeding
system regarding the orientation rate, the feeding velocity, and the
required nozzle pressure is presented.
Abstract: In order to be competitive, companies have to reduce
their production costs while meeting increasing quality requirements.
Therefore, companies try to plan their assembly processes as detailed
as possible. However, increasing product individualization leading to
a higher number of variants, smaller batch sizes and shorter product
life cycles raise the question to what extent the effort of detailed
planning is still justified. An important approach in this field of
research is the concept of determining the economic planning depth
for assembly process planning based on production specific
influencing factors. In this paper first solution hypotheses as well as a
first draft of the resulting method will be presented.
Abstract: Excessive fretting wear at the taper-trunnion junction
(trunnionosis) apparently contributes to the high failure rates of hip
implants. Implant wear and corrosion lead to the release of metal
particulate debris and subsequent release of metal ions at the tapertrunnion
surface. This results in a type of metal poisoning referred to
as metallosis. The consequences of metal poisoning include;
osteolysis (bone loss), osteoarthritis (pain), aseptic loosening of the
prosthesis and revision surgery. Follow up after revision surgery,
metal debris particles are commonly found in numerous locations. Background: A stable connection between the femoral ball head
(taper) and stem (trunnion) is necessary to prevent relative motions
and corrosion at the taper junction. Hence, the importance of
component assembly cannot be over-emphasized. Therefore, the aim
of this study is to determine the influence of head-stem junction
assembly by press fitting and the subsequent
disengagement/disassembly on the connection strength between the
taper ball head and stem. Methods: CoCr femoral heads were assembled with High stainless
hydrogen steel stem (trunnion) by Push-in i.e. press fit; and
disengaged by pull-out test. The strength and stability of the two
connections were evaluated by measuring the head pull-out forces
according to ISO 7206-10 standards. Findings: The head-stem junction strength linearly increases with
assembly forces.
Abstract: In this study, failure analysis of pipe system at a micro
hydroelectric power plant is investigated. Failure occurred at the pipe
system in the powerhouse during shut down operation of the water
flow by a valve. This locking had caused a sudden shock wave, also
called “Water-hammer effect”, resulting in noise and inside pressure
increase. After visual investigation of the effect of the shock wave on
the system, a circumference crack was observed at the pipe flange
weld region. To establish the reason for crack formation, calculations
of pressure and stress values at pipe, flange and welding seams were
carried out and concluded that safety factor was high (2.2), indicating
that no faulty design existed. By further analysis, pipe system and
hydroelectric power plant was examined. After observations it is
determined that the plant did not include a ventilation nozzle (air
trap), that prevents the system of sudden pressure increase inside the
pipes which is caused by water-hammer effect. Analyses were carried
out to identify the influence of water-hammer effect on inside
pressure increase and it was concluded that, according Jowkowsky’s
equation, shut down time is effective on inside pressure increase. The
valve closing time was uncertain but by a shut down time of even one
minute, inside pressure would increase by 7.6 bar (working pressure
was 34.6 bar). Detailed investigations were also carried out on the
assembly of the pipe-flange system by considering technical
drawings. It was concluded that the pipe-flange system was not
installed according to the instructions. Two of five weld seams were
not applied and one weld was carried out faulty. This incorrect and
inadequate weld seams resulted in; insufficient connection of the pipe
to the flange constituting a strong notch effect at weld seam regions,
increase in stress values and the decrease of strength and safety
factor.
Abstract: Spacer grid assembly supporting the nuclear fuel rods
is an important concern in the design of structural components of a
Pressurized Water Reactor (PWR). The spacer grid is composed by
springs and dimples which are formed from a strip sheet by means of
blanking and stamping processes. In this paper, the blanking process
and tooling parameters are evaluated by means of a 2D plane-strain
finite element model in order to evaluate the punch load and quality
of the sheared edges of Inconel 718 strips used for nuclear spacer
grids. A 3D finite element model is also proposed to predict the
tooling loads resulting from the stamping process of a preformed
Inconel 718 strip and to analyse the residual stress effects upon the
spring and dimple design geometries of a nuclear spacer grid.
Abstract: The output error of the globoidal cam mechanism can
be considered as a relevant indicator of mechanism performance,
because it determines kinematic and dynamical behavior of
mechanical transmission. Based on the differential geometry and the
rigid body transformations, the mathematical model of surface
geometry of the globoidal cam is established. Then we present the
analytical expression of the output error (including the transmission
error and the displacement error along the output axis) by considering
different manufacture and assembly errors. The effects of the center
distance error, the perpendicular error between input and output axes
and the rotational angle error of the globoidal cam on the output error
are systematically analyzed. A globoidal cam mechanism which is
widely used in automatic tool changer of CNC machines is applied for
illustration. Our results show that the perpendicular error and the
rotational angle error have little effects on the transmission error but
have great effects on the displacement error along the output axis. This
study plays an important role in the design, manufacture and assembly
of the globoidal cam mechanism.
Abstract: The work aims to develop a robot in the form of
autonomous vehicle to detect, inspection and mapping of
underground pipelines through the ATmega328 Arduino platform.
Hardware prototyping is very similar to C / C ++ language that
facilitates its use in robotics open source, resembles PLC used in
large industrial processes. The robot will traverse the surface
independently of direct human action, in order to automate the
process of detecting buried pipes, guided by electromagnetic
induction. The induction comes from coils that send the signal to the
Arduino microcontroller contained in that will make the difference in
intensity and the treatment of the information, and then this
determines actions to electrical components such as relays and
motors, allowing the prototype to move on the surface and getting the
necessary information. This change of direction is performed by a
stepper motor with a servo motor. The robot was developed by
electrical and electronic assemblies that allowed test your application.
The assembly is made up of metal detector coils, circuit boards and
microprocessor, which interconnected circuits previously developed
can determine, process control and mechanical actions for a robot
(autonomous car) that will make the detection and mapping of buried
pipelines plates. This type of prototype can prevent and identifies
possible landslides and they can prevent the buried pipelines suffer an
external pressure on the walls with the possibility of oil leakage and
thus pollute the environment.