Search results for: Automotive part manufacturing measurement

Authors: Venkatesh Bagaria, Nagesh AS, Varun AV

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In the domain of machine vision, the measurement of length is done using cameras where the accuracy is directly proportional to the resolution of the camera and inversely to the size of the object. Since most of the pixels are wasted imaging the entire body as opposed to just imaging the edges in a conventional system, a double aperture system is constructed to focus on the edges to measure at higher resolution. The paper discusses the complexities and how they are mitigated to realize a practical machine vision system.

Keywords: Machine Vision, double aperture camera, accurate length measurement

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Authors: Byung-Soo Shin, Nam-Seok Kim, Sang-Kyu Lee, O-Hyun Keum

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This analysis investigates the distortion of flow measurement and the increase of cavitation along orifice flowmeter. The analysis using the numerical method (CFD) validated the distortion of flow measurement through the inlet velocity profile considering the convergence and grid dependency. Realizable k-e model was selected and y+ was about 50 in this numerical analysis. This analysis also estimated the vulnerability of cavitation effect due to inlet velocity profile. The investigation concludes that inclined inlet velocity profile could vary the pressure which was measured at pressure tab near pipe wall and it led to distort the pressure values ranged from -3.8% to 5.3% near the orifice plate and to make the increase of cavitation. The investigation recommends that the fully developed inlet velocity flow is beneficial to accurate flow measurement in orifice flowmeter.

Keywords: Orifice, k-e model, CFD

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Authors: Ingy A. El-Khouly, Khaled S. El-Kilany, Aziz E. El-Sayed

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The process of wafer fabrication is arguably the most technologically complex and capital intensive stage in semiconductor manufacturing. This large-scale discrete-event process is highly reentrant, and involves hundreds of machines, restrictions, and processing steps. Therefore, production control of wafer fabrication facilities (fab), specifically scheduling, is one of the most challenging problems that this industry faces. Dispatching rules have been extensively applied to the scheduling problems in semiconductor manufacturing. Moreover, lot release policies are commonly used in this manufacturing setting to further improve the performance of such systems and reduce its inherent variability. In this work, simulation is used in the scheduling of re-entrant flow shop manufacturing systems with an application in semiconductor wafer fabrication; where, a simulation model has been developed for the Intel Five-Machine Six Step Mini-Fab using the ExtendTM simulation environment. The Mini-Fab has been selected as it captures the challenges involved in scheduling the highly re-entrant semiconductor manufacturing lines. A number of scenarios have been developed and have been used to evaluate the effect of different dispatching rules and lot release policies on the selected performance measures. Results of simulation showed that the performance of the Mini-Fab can be drastically improved using a combination of dispatching rules and lot release policy.

Keywords: Dispatching rules, lot release policy, re-entrant flowshop, semiconductor manufacturing.

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Authors: Jaemyoung Lee

Abstract:

We propose a new fiber lens structure for large distance measurement in which a polymer layer is added to a conventional fiber lens. The proposed fiber lens can adjust the working distance by properly choosing the refractive index and thickness of the polymer layer. In our numerical analysis for the fiber lens radius of 120 μm, the working distance of the proposed fiber lens is about 10 mm which is about 30 times larger than conventional fiber lens.

Keywords: fiber lens, distance measurement, collimation.

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Authors: Sumachaya Harnsukworapanich, Tetsuo Ichimori

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The apportionment method is used by many countries, to calculate the distribution of seats in political bodies. For example, this method is used in the United States (U.S.) to distribute house seats proportionally based on the population of the electoral district. Famous apportionment methods include the divisor methods called the Adams Method, Dean Method, Hill Method, Jefferson Method and Webster Method. Sometimes the results from the implementation of these divisor methods are unfair and include errors. Therefore, it is important to examine the optimization of this method by using a bias measurement to figure out precise and fair results. In this research we investigate the bias of divisor methods in the U.S. Houses of Representatives toward large and small states by applying the Stolarsky Mean Method. We compare the bias of the apportionment method by using two famous bias measurements: the Balinski and Young measurement and the Ernst measurement. Both measurements have a formula for large and small states. The Third measurement however, which was created by the researchers, did not factor in the element of large and small states into the formula. All three measurements are compared and the results show that our measurement produces similar results to the other two famous measurements.

Keywords: Apportionment, Bias, Divisor, Fair, Simulation

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Authors: C. Malça, N. Alves, A. Mateus

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This work was one of the tasks of the Manufacturing2Client project, whose objective was to develop a frontal deflector to be commercialized in the automotive industry, using new project and manufacturing methods. In this task, in particular, it was proposed to develop the ability to predict computationally the aerodynamic influence of flow in vehicles, in an effort to reduce fuel consumption in vehicles from class 3 to 8. With this aim, two deflector models were developed and their aerodynamic performance analyzed. The aerodynamic study was done using the Computational Fluid Dynamics (CFD) software Ansys CFX and allowed the calculation of the drag coefficient caused by the vehicle motion for the different configurations considered. Moreover, the reduction of diesel consumption and carbon dioxide (CO2) emissions associated with the optimized deflector geometry could be assessed.

Keywords: Aerodynamic analysis, CFD, CO2 emissions, Drag coefficient, Frontal deflector, Fuel consumption.

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Authors: Mariayee Doraisamy, Suhaimi Bin Ibrahim, Mohd Naz’ri Mahrin

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There are several methods to monitor software projects and the objective for monitoring is to ensure that the software projects are developed and delivered successfully. A performance measurement is a method that is closely associated with monitoring and it can be scrutinized by looking at two important attributes which are efficiency and effectiveness both of which are factors that are important for the success of a software project. Consequently, a successful steering is achieved by monitoring and controlling a software project via the performance measurement criteria and metrics. Hence, this paper is aimed at identifying the performance measurement criteria and the metrics for monitoring the performance of a software project by using the Goal Question Metrics (GQM) approach. The GQM approach is utilized to ensure that the identified metrics are reliable and useful. These identified metrics are useful guidelines for project managers to monitor the performance of their software projects.

Keywords: Software project performance, Goal Question Metrics, Performance Measurement Criteria, Metrics.

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Authors: Nor Fazlina Iryani Abdul Hamid, Mohamad Khatim Hasan

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Numbers of software quality measurement system have been implemented over the past few years, but none of them focuses on telecommunication industry. Software quality measurement system for telecommunication industry was a system that could calculate the quality value of the measured software that totally focused in telecommunication industry. Before designing a system, quality factors, quality attributes and quality metrics were identified based on literature review and survey. Then, using the identified quality factors, quality attributes and quality metrics, quality model for telecommunication industry was constructed. Each identified quality metrics had its own formula. Quality value for the system was measured based on the quality metrics and aggregated by referring to the quality model. It would classify the quality level of the software based on Net Satisfaction Index (NSI). The system was designed using object-oriented approach in web-based environment. Thus, existing of software quality measurement system was important to both developers and users in order to produce high quality software product for telecommunication industry.

Keywords: Software Quality, Quality Measurement, Object-oriented Approach, Net satisfaction Index.

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Authors: Yue-Der Lin, Ya-Hsueh Chien, Yen-Ting Lin, Shih-Fan Wang, Cheng-Lun Tsai, Ching-Che Tsai

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Capacitive electrocardiogram (ECG) measurement is an attractive approach for long-term health monitoring. However, there is little literature available on its implementation, especially for multichannel system in standard ECG leads. This paper begins from the design criteria for capacitive ECG measurement and presents a multichannel limb-lead capacitive ECG system with conductive fabric tapes pasted on a double layer PCB as the capacitive sensors. The proposed prototype system incorporates a capacitive driven-body (CDB) circuit to reduce the common-mode power-line interference (PLI). The presented prototype system has been verified to be stable by theoretic analysis and practical long-term experiments. The signal quality is competitive to that acquired by commercial ECG machines. The feasible size and distance of capacitive sensor have also been evaluated by a series of tests. From the test results, it is suggested to be greater than 60 cm2 in sensor size and be smaller than 1.5 mm in distance for capacitive ECG measurement.

Keywords: capacitive driven-body (CDB) circuit, capacitive electrocardiogram (ECG) measurement, capacitive sensor, conductive fabric tape, power-line interference (PLI).

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Authors: B.-A. Behrens, H. J. Maier, A. Neumann, J. Moritz, S. Hübner, T. Gretzki, F. Nürnberger, A. Spiekermeier

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Press-hardened profiles are used e.g. for automotive applications in order to improve light weight construction due to the high reachable strength. The application of interior water-air spray cooling contributes to significantly reducing the cycle time in the production of heat-treated tubes. This paper describes a new manufacturing method for producing press-hardened hollow profiles by means of an additional interior cooling based on a water-air spray. Furthermore, this paper provides the results of thorough investigations on the properties of press-hardened tubes in dependence of varying spray parameters.

Keywords: 22MnB5, hollow profiles, press hardening, tubes, water-air spray cooling.

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Authors: Mohammad Javad Mollakazemi, Farhad Asadi, Aref Ghafouri

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In this paper, we considered and applied parametric modeling for some experimental data of dynamical system. In this study, we investigated the different distribution of output measurement from some dynamical systems. Also, with variance processing in experimental data we obtained the region of nonlinearity in experimental data and then identification of output section is applied in different situation and data distribution. Finally, the effect of the spanning the measurement such as variance to identification and limitation of this approach is explained.

Keywords: Gaussian process, Nonlinearity distribution, Particle filter.

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Authors: Yoshio Kurosawa, Takao Yamaguchi

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High frequency automotive interior noise above 500 Hz considerably affects automotive passenger comfort. To reduce this noise, sound insulation material is often laminated on body panels or interior trim panels. For a more effective noise reduction, the sound reduction properties of this laminated structure need to be estimated. We have developed a new calculate tool that can roughly calculate the sound absorption and insulation properties of laminate structure and handy for designers. In this report, the outline of this tool and an analysis example applied to floor mat are introduced.

Keywords: Automobile, acoustics, porous material, Transfer Matrix Method.

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Authors: N. Javadian, J. Rezaeian, Y. Maali

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In this paper a multi-objective nonlinear programming model of cellular manufacturing system is presented which minimize the intercell movements and maximize the sum of reliability of cells. We present a genetic approach for finding efficient solutions to the problem of cell formation for products having multiple routings. These methods find the non-dominated solutions and according to decision makers prefer, the best solution will be chosen.

Keywords: Cellular Manufacturing, Genetic Algorithm, Multiobjective, Life-Cycle.

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Authors: N. Miklavčič, U. Kugovnik, N. Galkina, P. Ribarič, R. Vončina

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Today the need for weather predictions is deeply rooted in the everyday life of people as well as it is in industry. The forecasts influence final decision-making processes in multiple areas from agriculture and prevention of natural disasters to air traffic regulations and solutions on a national level for health, security, and economic problems. Namely in Slovenia, alongside other existing forms of application, weather forecasts are adopted for the prognosis of electrical current transmission through powerlines. Meteorological parameters are one of the key factors which need to be considered in estimations of the reliable supply of electrical energy to consumers. And like for any other measured value, the knowledge about measurement uncertainty is critical also for the secure and reliable supply of energy. The estimation of measurement uncertainty grants us a more accurate interpretation of data, a better quality of the end results, and even a possibility of improvement of weather forecast models.

Keywords: Measurement uncertainty, microscale meteorological model, CALMET meteorological station, orthogonal regression.

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Authors: Lenka Hurtalová, Eva Tillová, Mária Chalupová, Juraj Belan, Milan Uhríčik

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The secondary alloy A226 is used for many automotive casting produced by mould casting and high pressure die casting. This alloy has excellent castability, good mechanical properties and cost-effectiveness. Production of primary aluminium alloys belong to heavy source fouling of life environs. The European Union calls for the emission reduction and reduction in energy consumption therefore increase production of recycled (secondary) aluminium cast alloys. The contribution is deal with influence of recycling on the quality of the casting made from A226 in automotive industry. The properties of the casting made from secondary aluminium alloys were compared with the required properties of primary aluminium alloys. The effect of recycling on microstructure was observed using combination different analytical techniques (light microscopy upon black-white etching, scanning electron microscopy - SEM upon deep etching and energy dispersive X-ray analysis - EDX). These techniques were used for the identification of the various structure parameters, which was used to compare secondary alloy microstructure with primary alloy microstructure.

Keywords: A226 secondary aluminium alloy, deep etching, mechanical properties, recycling foundry aluminium alloy.

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Authors: Marco Ryll, Svetan Ratchev

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This paper discusses the applicability of the Data Distribution Service (DDS) for the development of automated and modular manufacturing systems which require a flexible and robust communication infrastructure. DDS is an emergent standard for datacentric publish/subscribe middleware systems that provides an infrastructure for platform-independent many-to-many communication. It particularly addresses the needs of real-time systems that require deterministic data transfer, have low memory footprints and high robustness requirements. After an overview of the standard, several aspects of DDS are related to current challenges for the development of modern manufacturing systems with distributed architectures. Finally, an example application is presented based on a modular active fixturing system to illustrate the described aspects.

Keywords: Flexible Manufacturing, Publish/Subscribe, Plug & Produce.

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Authors: Shilpesh R. Rajpurohit, Harshit K. Dave

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Fused deposition modeling (FDM) gains popularity in recent times, due to its capability to create prototype as well as functional end use product directly from CAD file. Parts fabricated using FDM process have mechanical properties comparable with those of injection-molded parts. However, performance of the FDM part is severally affected by the poor mechanical properties of the part due to nature of layered structure of printed part. Mechanical properties of the part can be improved by proper selection of process variables. In the present study, a comparative study between unidirectional and bidirectional raster angle has been carried out at a combination of different layer height and raster width. Unidirectional raster angle varied at five different levels, and bidirectional raster angle has been varied at three different levels. Fabrication of tensile specimen and tensile testing of specimen has been conducted according to ASTM D638 standard. From the results, it can be observed that higher tensile strength has been obtained at 0° raster angle followed by 45°/45° raster angle, while lower tensile strength has been obtained at 90° raster angle. Analysis of fractured surface revealed that failure takes place along with raster deposition direction for unidirectional and zigzag failure can be observed for bidirectional raster angle.

Keywords: Additive manufacturing, fused deposition modeling, raster angle, tensile strength.

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Authors: Lari Kela, Pekka Vähäoja

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Pressure wave velocity in a hydraulic system was determined using piezo pressure sensors without removing fluid from the system. The measurements were carried out in a low pressure range (0.2 – 6 bar) and the results were compared with the results of other studies. This method is not as accurate as measurement with separate measurement equipment, but the fluid is in the actual machine the whole time and the effect of air is taken into consideration if air is present in the system. The amount of air is estimated by calculations and comparisons between other studies. This measurement equipment can also be installed in an existing machine and it can be programmed so that it measures in real time. Thus, it could be used e.g. to control dampers.

Keywords: Bulk modulus, pressure wave, sound velocity.

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Authors: Amira Zrelli, Tahar Ezzeddine

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Measurement and monitoring of temperature, humidity and strain variation are very requested in great fields and areas such as structural health monitoring (SHM) systems. Currently, the use of fiber Bragg grating sensors (FBGS) is very recommended in SHM systems due to the specifications of these sensors. In this paper, we present the theory of Bragg sensor, therefore we try to measure the efficient variation of strain, temperature and humidity (SV, ST, SH) using Bragg sensor. Thus, we can deduce the fundamental relation between these parameters and the wavelength of Bragg sensor.

Keywords: Optical fiber, strain, temperature, humidity, measurement, Bragg sensor, SHM.

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Authors: Martin Kendra, Tomas Skrucany, Jaroslav Masek

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The noise is one of the negative elements which affects the human health. This article presents the measurement of emitted noise by road vehicle and its parts during the operation. Measurement was done in the interior of common passenger cars with a digital sound meter. The results compare the noise value in different cars with different body shape, which influences the driver’s health. Transport has considerable ecological effects; many of them are detrimental to environmental sustainability. Roads and traffic exert a variety of direct and mostly detrimental effects on nature.

Keywords: Driver, noise measurement, passenger road vehicle, road transport.

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Authors: Ola I. S. El Dardery, Ismail Gomaa, Adel R. M. Rayan, Ghada El Khayat, Sara H. Sabry

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Continuous improvement activities are becoming a key organizational success factor; those improvement activities include but are not limited to kaizen, six sigma, lean production, and continuous improvement projects. Kaizen is a Japanese philosophy of continuous improvement by making small incremental changes to improve an organization’s performance, reduce costs, reduce delay time, reduce waste in production, etc. This research aims at proposing a measuring system for kaizen activities from a sustainable balanced scorecard perspective. A survey was developed and disseminated among kaizen experts in both Egypt and Japan with the purpose of allocating key performance indicators for both kaizen process (critical success factors) and result (kaizen benefits) into the five sustainable balanced scorecard perspectives. This research contributes to the extant literature by presenting a kaizen measurement of both kaizen process and results that will illuminate the benefits of using kaizen. Also, the presented measurement can help in the sustainability of kaizen implementation across various sectors and industries. Thus, grasping the full benefits of kaizen implementation will contribute to the spread of kaizen understanding and practice. Also, this research provides insights on the social and cultural differences that would influence the kaizen success. Determining the combination of the proper kaizen measures could be used by any industry, whether service or manufacturing for better kaizen activities measurement. The comparison between Japanese implementation of kaizen, as the pioneers of continuous improvement, and Egyptian implementation will help recommending better practices of kaizen in Egypt and contributing to the 2030 sustainable development goals. The study results reveal that there is no significant difference in allocating kaizen benefits between Egypt and Japan. However, with regard to the critical success factors some differences appeared reflecting the social differences and understanding between both countries, a single integrated measurement was reached between the Egyptian and Japanese allocation highlighting the Japanese experts’ opinion as the ultimate criterion for selection.

Keywords: continuous improvements, kaizen, performance, sustainable balanced scorecard

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Authors: M. Mahboubkhah, H. Fayazfar

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In this research, Forming Limit Diagrams for supertension sheet metals which are using in automobile industry have been obtained. The exerted strains to sheet metals have been measured with four different methods and the errors of each method have also been represented. These methods have been compared with together and the most efficient and economic way of extracting of the exerted strains to sheet metals has been introduced. In this paper total error and uncertainty of FLD extraction procedures have been derived. Determination of the measurement uncertainty in extracting of FLD has a great importance in design and analysis of the sheet metal forming process.

Keywords: Forming Limit Diagram, Major and Minor Strain, Measurement Uncertainty.

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Authors: Syed Javed Arif, Mohd Ayyub Khan, Saleem Anwar Khan

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In this paper, a simple method is presented for measurement of power frequency deviations. A phase locked loop (PLL) is used to multiply the signal under test by a factor of 100. The number of pulses in this pulse train signal is counted over a stable known period, using decade driving assemblies (DDAs) and flip-flops. These signals are combined using logic gates and then passed through decade counters to give a unique combination of pulses or levels, which are further encoded. These pulses are equally suitable for both control applications and display units. The experimental circuit developed gives a resolution of 1 Hz within the measurement period of 20 ms. The proposed circuit is also simulated in Verilog Hardware Description Language (VHDL) and implemented using Field Programing Gate Arrays (FPGAs). A Mixed signal Oscilloscope (MSO) is used to observe the results of FPGA implementation. These results are compared with the results of the proposed circuit of discrete components. The proposed system is useful for frequency deviation measurement and control in power systems.

Keywords: Frequency measurement, digital control, phase locked loop, encoding, Verilog HDL.

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Authors: Yung-Yuan Chen, Kuen-Long Leu

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FlexRay, as a communication protocol for automotive control systems, is developed to fulfill the increasing demand on the electronic control units for implementing systems with higher safety and more comfort. In this work, we study the impact of radiation-induced soft errors on FlexRay-based steer-by-wire system. We injected the soft errors into general purpose register set of FlexRay nodes to identify the most critical registers, the failure modes of the steer-by-wire system, and measure the probability distribution of failure modes when an error occurs in the register file.

Keywords: Soft errors, FlexRay, fault injection, steer-by-wirer

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Authors: Farhad Asadi, S. Hossein Sadati

Abstract:

Bayesian approach can be used for parameter identification and extraction in state space models and its ability for analyzing sequence of data in dynamical system is proved in different literatures. In this paper, adaptive Kalman filter with Bayesian approach for identification of variances in measurement parameter noise is developed. Next, it is applied for estimation of the dynamical state and measurement data in discrete linear dynamical system. This algorithm at each step time estimates noise variance in measurement noise and state of system with Kalman filter. Next, approximation is designed at each step separately and consequently sufficient statistics of the state and noise variances are computed with a fixed-point iteration of an adaptive Kalman filter. Different simulations are applied for showing the influence of noise variance in measurement data on algorithm. Firstly, the effect of noise variance and its distribution on detection and identification performance is simulated in Kalman filter without Bayesian formulation. Then, simulation is applied to adaptive Kalman filter with the ability of noise variance tracking in measurement data. In these simulations, the influence of noise distribution of measurement data in each step is estimated, and true variance of data is obtained by algorithm and is compared in different scenarios. Afterwards, one typical modeling of nonlinear state space model with inducing noise measurement is simulated by this approach. Finally, the performance and the important limitations of this algorithm in these simulations are explained. 

Keywords: adaptive filtering, Bayesian approach Kalman filtering approach, variance tracking

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Authors: Babak Saboori, Behzad Saboori, Johan S. Carlson, Rikard Söderberg

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As product life cycle becomes less and less every day, having flexible manufacturing processes for any companies seems more demanding. In the assembling of closures, i.e. opening parts in car body, hemming process is the one which needs more attention. This paper focused on the robot roller hemming process and how to reduce its cycle time by introducing a fast roller hemming process. A robot roller hemming process of a tailgate of Saab 93 SportCombi model is investigated as a case study in this paper. By applying task separation, robot coordination, and robot cell configuration principles in the roller hemming process, three alternatives are proposed, developed, and remarkable reduction in cycle times achieved [1].

Keywords: Cell configuration, cycle time, robot coordination, roller hemming.

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Authors: Jan Busch, Peter Nyhuis

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.

Keywords: Aerodynamic feeding system, genetic algorithm, multi-objective optimization.

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Authors: F.B. Georgise, K. D. Thoben, M. Seifert

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This paper presents a research agenda on the SCOR model adaptation. SCOR model is designated to measure supply chain performance and logistics impact across the boundaries of individual organizations. It is at its growing stage of its life cycle and is enjoying the leverage of becoming the industry standard. The SCOR model has been developed and used widely in developed countries context. This research focuses on the SCOR model adaptation for the manufacturing industry in developing countries. With a necessary understanding of the characteristics, difficulties and problems of the manufacturing industry in developing countries- supply chain; consequently, we will try to designs an adapted model with its building blocks: business process model, performance measures and best practices.

Keywords: developing countries, manufacturing industry, SCOR model adaptation

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Authors: Nabli L., Dhouibi H., Collart Dutilleul S., Craye E.

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The existence of maximal durations drastically modifies the performance evaluation in Discrete Event Systems (DES). The same particularity may be found on systems where the associated constraints do not concern the time. For example weight measures, in chemical industry, are used in order to control the quantity of consumed raw materials. This parameter also takes a fundamental part in the product quality as the correct transformation process is based upon a given percentage of each essence. Weight regulation therefore increases the global productivity of the system by decreasing the quantity of rejected products. In this paper we present an approach based on mixing different characteristics theories, the fuzzy system and Petri net system to describe the behaviour. An industriel application on a tobacco manufacturing plant, where the critical parameter is the weight is presented as an illustration.

Keywords: Petri Net, Manufacturing systems, Performance evaluation, Fuzzy logic, Tolerant system.

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Authors: Kati Kõrbe Kaare, Ott Koppel

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Transport and logistics are the lifeblood of societies. There is a strong correlation between overall growth in economic activity and growth of transport. The movement of people and goods has the potential for creating wealth and prosperity, therefore the state of transportation infrastructure and especially the condition of road networks is often a governmental priority. The design, building and maintenance of national roads constitute a substantial share of government budgets. Taking into account the magnitude and importance of these investments, the expedience, efficiency and sustainability of these projects are of great public interest. This paper provides an overview of supply chain management principles applied to road construction. In addition, road construction performance measurement systems and ICT solutions are discussed. Road construction in Estonia is analyzed. The authors propose the development of a national performance measurement system for road construction.

Keywords: ICT in road construction, key performance indicators, quality performance measurement, road construction supply chain.

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