Assembly Cost Research Articles

Design and development of self-aligning troughing idler used in belt conveyor system

Self-aligning idler provides a unique solution for rectifying the belt mistracking and aligning the belt to its centerline. A misaligned conveyor will cause the belt to run off-center to one side. In this study, the existing self-aligning idler assembly being used for belt conveyors has been analyzed and an alternate assembly is designed to overcome limitations in the existing system.The newly designed assembly takes an edge over the existing assembly as it gives flexibility for adjusting the troughing angle and varying design capacity. The taper rollers are used instead of flat idler rollers which are self-actuating and provide a quick response system. The idler bracket is also modified to optimize the weight and cost of the total idler assembly. For the first time, the newly developed assembly offers the advantage of variable conveyor capacity and Troughing angle adjustment. Also, the assembly assures the lightweight construction to optimize conveyor power requirements.

Fast Formation of Matrices for Least-Squares Fitting by Tensor-Product Spline Surfaces

Least-squares fitting by tensor-product spline surfaces is a classical method for approximating unstructured data, which is widely used in industry. However, assembling the system of equations via the straightforward approach can be quite time–consuming. In this paper, we propose to accelerate this process by employing the technique of sum factorization, which is frequently used in the context of isogeometric analysis. Our approach consists of two steps. First, we introduce a regular grid onto which the parameters of the data are projected. Consequently, the expressions of the matrix entries take a form that admits the use of sum factorization, which is then employed in the second step. We provide a detailed complexity analysis and quantify the expected relative assembly costs. Several examples, including an example involving industrial data, demonstrate how the choice of the grid influences speed and precision, and confirm the expected time savings of the proposed method. • We use sum factorization to accelerate formation of least squares matrices. • We provide detailed complexity analysis. • Despite data projection to a regular grid, the error is comparable to the baseline. • Several examples (including an industrial geometry) confirm the findings.

3D Bioprinted Hydrogel Microfluidic Devices for Parallel Drug Screening.

Conventional high-throughput screening (HTS) platforms suffer from the need for large cell volumes, high reagent consumption, significant assembly cost, and handling efforts. The assembly of three-dimensional (3D) bioprinted hydrogel-based microfluidic chips within platforms can address these problems. We present a continuous and seamless manufacturing approach to create a bioprinted microfluidic chips with a circular pattern scalable toward HTS platforms. Digital light processing 3D bioprinting is used to tune the local permeability of our chip, made of polyethylene glycol diacrylate and cell-laden gelatin methacryloyl, for creating predefined gradients of biochemical properties. We measured the flow-induced physical characteristics, the mass transport of drug agents, and the biological features of the proposed chip. We measured reactive oxygen species from the encapsulated cells through an integrated process and showed the capacity of the hydrogel-based chip for creating drug/agent gradients. This work introduces a chip design based on a hydrogel that can be changed and could be used for modern HTS platforms such as in vitro organoids.

Introducing Robotized Stator Cable Winding to Rotating Electric Machines

Following environmental concerns and the rapid digitalization of our society, we are currently experiencing an extensive electrification and industrial revolution. High numbers of electric machines thus need to be assembled for varying applications, including vehicle propulsion and renewable energy conversion. Cable winding is an alternative stator winding technology for electric machines that has been utilized for such applications, so far in smaller series or in prototype machines. The presented work introduces the first concept for automated stator cable winding of rotating electric machines. This concept could enable higher production volumes of cable wound machines and a unique flexibility in handling different machines, in line with Industry 4.0. Robotized stator cable winding is evaluated here for five very different rotating machine designs, through simulations and analytical extrapolation of previous experimental winding results. Potential cycle time and assembly cost savings are indicated compared to manual and lower volume conventional automation, while it is not possible to compete in the present form with existing very high-volume conventional winding automation for smaller machines. Future experimental work is pointed out on handling larger winding cables and special machine designs, and on increased robustness and optimization.

An ultra-wideband origami microwave absorber

Microwave absorbers have been used to mitigate signal interference, and to shield electromagnetic systems. Two different types of absorbers have been presented: (a) low-cost narrowband absorbers that are simple to manufacture, and (b) expensive wideband microwave absorbers that are based on complex designs. In fact, as designers try to increase the bandwidth of absorbers, they typically increase their complexity with the introduction of several electromagnetic components (e.g., introduction of multi-layer designs, introduction of multiple electromagnetic resonators, etc.,), thereby increasing their fabrication cost. Therefore, it has been a challenge to design wideband absorbers with low cost of fabrication. To address this challenge, we propose a novel design approach that combines origami math with electromagnetics to develop a simple to manufacture ultra-wideband absorber with minimal fabrication and assembly cost. Specifically, we utilize a Tachi–Miura origami pattern in a honeycomb configuration to create the first absorber that can maintain an absorptivity above 90% in a 24.6:1 bandwidth. To explain the ultra-wideband behavior of our absorber, we develop analytical models based on the transmission-reflection theory of electromagnetic waves through a series of inhomogeneous media. The ultra-wideband performance of our absorber is validated and characterized using simulations and measurements.

The Optimization of Vapor Compression Type for Desalination of Seawater Using the DFMA Method

The design of vapor compression type distillation using the design for manufacture and assembly (DFMA) method was discussed in this article. The efficacy of seawater desalination is the primary source of non-conventional fresh water in a large number of countries around the world. The distillation process can satisfy the demands for high-quality fresh water by utilizing seawater. DFMA is a technique for product development and improvement that could be used to simplify the manufacturing process and reduce assembly costs. This research focuses on creating an effective vapor compression-type desalination device. The DFMA method is used in this reverse engineering study. According to the findings of this study, the total assembly time of 22 components was 7932 seconds. Compared to the previous process, processing time efficiency increased by 4.1 %.

Review article on fast dissolving tablets

For the majority of patients, oral administration is the preferred method of drug delivery. Tablets and capsules are the most often used oral solid dose forms all over the world. Around 30% of patients have had trouble swallowing tablets and capsules, according to reports. When spit comes into contact with the dose frames, they swiftly degrade, releasing the medication, reducing the amount of water required throughout the organisation. These distinguishing characteristics appeal to both paediatric and geriatric patients. Gulping difficulties with standard pills and containers are frequent in people of all ages, but especially in the elderly and dysphagia patients. [1] Furthermore, robust oral conveyance frameworks do not necessitate sterilisation. The rapid dissolving drug delivery system has played an important role in adapting and meeting the needs of patients. The oral course organisation is the most important method that has been credited with having a fundamental impact. The conventional tablet is widely recognised as the most popular pharmaceutical measurement shape because of its ease of transportation and low assembly cost. These structures break down fast in the mouth, increasing bioavailability. Mouth dissolving doses are a type of quick-dissolving measuring construction.

Transcriptional Tuning of Mevalonate Pathway Enzymes to Identify the Impact on Limonene Production in Escherichia coli.

Heterologous production of limonene in microorganisms through the mevalonate (MVA) pathway has traditionally imposed metabolic burden and reduced cell fitness, where imbalanced stoichiometries among sequential enzymes result in the accumulation of toxic intermediates. Although prior studies have shown that changes to mRNA stability, RBS strength, and protein homology can be effective strategies for balancing enzyme levels in the MVA pathway, testing different variations of these parameters often requires distinct genetic constructs, which can exponentially increase assembly costs as pathways increase in size. Here, we developed a multi-input transcriptional circuit to regulate the MVA pathway, where four chemical inducers, l-arabinose (Ara), choline chloride (Cho), cuminic acid (Cuma), and isopropyl β-d-1-thiogalactopyranoside (IPTG), each regulate one of four orthogonal promoters. We tested modular transcriptional regulation of the MVA pathway by placing this circuit in an engineered Escherichia coli “marionette” strain, which enabled systematic and independent tuning of the first three enzymes (AtoB, HMGS, and HMGR) in the MVA pathway. By systematically testing combinations of chemical inducers as inputs, we investigated relationships between the expressions of different MVA pathway submodules, finding that limonene yields are sensitive to the coordinated transcriptional regulation of HMGS and HMGR.

Assembly Sequence Planning: A Review

Background: Assembly Sequence Planning (ASP) is an important stage in the process of product design and manufacturing. A reasonable assembly sequence can reduce the complexity of assembly operations, reduce the number of tools and fixtures, improve assembly efficiency, reduce assembly time, and reduce assembly costs. Methods: The purpose of this paper is to review the objective function, constraint conditions, and the solving methods of the ASP. Conclusion: The research methods can be roughly divided into three categories: graph-based method, knowledge-based method, and artificial intelligence algorithm. The advantages and disadvantages of the three methods are compared. Finally, future research is discussed, which could provide a reference for the ASP.

An efficient hybrid integer and categorical particle swarm optimization algorithm for the multi-mode multi-project inverse scheduling problem in turbine assembly workshop

This article deals with the multi-mode multi-project inverse scheduling problem of the turbine assembly workshop in a Chinese electric power station equipment manufacturing firm considering some unexpected disturbances in the assembly process, such as materials delay, equipment failure and parts rework, etc. The objective is to optimize the assembly cost in inverse scheduling under the constraints of due date, worker modes, cranes, etc. A modified integer and categorical particle swarm optimization algorithm combined with Tabu search (MICPSO-TS) is proposed. In the proposed MICPSO-TS, double-vector encoding is presented to show the execution modes of activities and overtime schedule of projects which are optimized by ICPSO and TS respectively. A hybrid heuristic decoding algorithm (HHDA) including project order selection rules, crane scheduling rules, resource reservation mechanism and overtime determination rules is proposed. Eventually, the feasibility and effectiveness of the proposed MICPSO-TS are verified by the experimental test data and a real-world engineering case.

A comparison study on the hydrodynamic performance of a buoyancy-distributed floating foundation in regular waves

The manufacturing and assembly costs have a great significance in floating foundations of offshore structures. This paper presents a novel buoyancy-distributed floating foundation (BDFF) based on modular design and validates its high hydrodynamic performance. A centralized ballast platform with a single-point mooring system and a distributed ballast platform with a multi-mooring system are designed for comparison. A series of tests with scaled models and numerical simulation work were conducted in regular waves. There is good agreement in the response amplitude operators (RAOs) for the experiments and the simulation with a bit of over-prediction. Additionally, the influence of wave frequencies and wave heights on the BDFF is also investigated. It is found that the model with a multi-point mooring system gives a moderate response and can be regarded as a linear system, while the model with a single-point mooring system has a large responsivity for high frequencies.

An Optimization Framework for Operational-Level Resource Composition in an Inclusive Manufacturing System

Abstract Manufacturing is an essential component of the economy, and globalization further influences it by the driving forces of outsourcing and distributed manufacturing with technological advances. However, the decreasing share in gross domestic product (GDP) and shrinking employment from the manufacturing sector have become concerning matters. Recently, the inclusive manufacturing paradigm has been proposed by concentrating on globally observed economic, environmental, and societal issues. This paper advances the concept of an inclusive manufacturing system (IMS) by developing an optimization-based model to enable resource composition scenarios. The developed model encapsulates an amalgamation of a realistic and complex production system, suppliers, manufacturers, assembly stations, logistics providers, and courier services. The model aims to optimize the cost and emission of manufacturing, assembly, and logistics systems while producing a product. The formulated optimization problem is discrete in nature with binary and integer decision variables and multiple complexities of nonlinear functions. Therefore, evolutionary techniques are exercised as solution approaches to handle the problem's complexity and size. A simulated case example has been designed to envision the inclusive manufacturing system by perceiving a real-life production scenario of labeling conveyor, a customized product engaged for most packaged items. The study reveals that network size influences cost and emission because of competitiveness among service providers to get the order. The result also insights that a significant share of the cost comes from production and assembling activities, whereas transportation services dominate over manufacturing-assembly activities in carbon emission.

Possibilities to Increase Assembly Line Productivity Using Different Management Approaches

A number of scientific methods are used to support productivity growth in companies, aimed at reducing waste, balancing assembly lines and supporting the introduction of automation into assembly processes. Their use in industrial practice is widespread, especially in large and medium-sized enterprises, and small businesses that use scientific methods to a limited extent. The aim of the research is to show the assembly process of throttle valves implemented in a small company, the effects of balancing the current assembly line and the effects of proposals of variant solutions on the automated assembly line and on the amount of hourly assembly production and costs per product. Within costs, two cost types are monitored: namely the hourly labor costs, and hourly machine costs. The sum of the hourly assembly line costs is determined by their sum. In the results section, the main sources of waste in the assembly process are identified, and eight proposals leading to the elimination of waste are processed. In the discussion, the individual proposals are evaluated in terms of the cost of one product, the hourly production of assembly and the tact times of assembly lines. The proposal that is evaluated as the best process is compared with the current state. The purpose of this article is to point out the advantages of the implementation of scientific methods in industrial practice, the achieved savings in the solved problem, and thus, to support those scientific methods in the management of assembly processes which are beginning to be used in greater extents by small businesses.

Functionalizing Framework Nucleic-Acid-Based Nanostructures for Biomedical Application.

Strategies for functionalizing diverse tetrahedral framework nucleic acids (tFNAs) have been extensively explored since the first successful fabrication of tFNA by Turberfield. One-pot annealing of at least four DNA single strands is the most common method to prepare tFNA, as it optimizes the cost, yield, and speed of assembly. Herein, the focus is on four key merits of tFNAs and their potential for biomedical applications. The natural ability of tFNA to scavenge reactive oxygen species, along with remarkable enhancement in cellular endocytosis and tissue permeability based on its appropriate size and geometry, promotes cell-material interactions to direct or probe cell behavior, especially to treat inflammatory and degenerative diseases. Moreover, the structural programmability of tFNA enables the development of static tFNA-based nanomaterials via engineering of functional oligonucleotides or therapeutic molecules, and dynamic tFNAs via attachment of stimuli-responsive DNA apparatuses, leading to potential applications in targeted therapies, tissue regeneration, antitumor strategies, and antibacterial treatment. Although there are impressive performance and significant progress, the challenges and prospects of functionalizing tFNA-based nanostructures are still indicated in this review.

Minimization of total manufacturing cost of a knuckle joint assembly by means of optimal tolerance allocation using various optimization algorithms

In the present work, the minimization of total manufacturing cost of an assembly considering tolerance allocation using various optimization algorithms have been addressed. Complex assembly which consists of more than one critical dimension with any one dimension of the part involved in more than one dimensional chain has been considered in this work. The manufacturing cost of the various parts of an assembly with tolerance allocation has been minimized using the cost tolerance model. The benchmark solution to the problem has been derived using Lagrange Multiplier (LM) method. The results are improved using Genetic Algorithm (GA) and Artificial Bee Colony (ABC) algorithm by considering the Alternate Nominal Dimension Selection (ANDS). The results have been compared with LM method and found GA outperformed ABC algorithm. Further the research has been extended by considering ANDS and Alternate Process Selection (APS) using Teaching-Learning Based Optimization (TLBO) algorithm and the results have been compared with benchmark solutions. The proposed method is suitable for any type of complex assembly. An Improved Knuckle Joint (IKJ) assembly has been chosen for the illustration of proposed methodology with an implementation strategy. From the results, it was noted that TLBO yielded better results in the aspect of minimizing the total manufacturing cost of IKJ assemblies.

Arterial Line Placement Pitfalls Can Be Demonstrated and Visualized With an Inexpensive, Wearable Trainer.

Radial arterial line placement is commonly performed in various clinical settings, including the emergency department. However, learners are successful on the first attempt only half of the time. Simulation can provide learners with procedure practice opportunities outside of clinical practice to increase confidence and chances of success. We set out to build an arterial line trainer that would be inexpensive and reusable, wearable, anatomically realistic, and echogenic to allow for ultrasound use. We also hoped to devise a clear option that would allow for demonstration of procedure pitfalls. The arterial line trainer requires 4 hours of assembly time and costs $160. This includes enough material to make 48 tissue pads. The ballistics gel pad is echogenic; it can be customized with clear gel for direct anatomic visualization or dyed gel for more realism. The trainer also has a pulsatile artery for practice using anatomic landmarks. Visualization of the following important arterial line placement pitfalls is possible: suboptimal angle of approach, inadequate advancement of the catheter, and through-and-through vessel puncture. Our inexpensive trainer can help physicians and physicians in training conceptualize, practice, and troubleshoot the pitfalls of arterial line placement. Training programs looking to help learners understand the mechanics of arterial line placement may find it a useful tool.

Novel flexible piezoelectric‐conductive Janus nanofibers integrated membrane with enhanced pressure sensing performance

AbstractExploitation of soft piezoelectric sensing materials is fundamental to the research of energy‐harvesting devices and wearable electronics. However, a big challenge of piezoelectric materials application in micro‐scale sensing systems is to address the restrictions of electrode compatibility, miniaturization, multistep assembly, and high cost. Here, we propose a simple strategy to develop the coinstantaneous construction of piezoelectric materials and nanoresistance networks by fabricating electrospun piezoelectric‐conductive (polyacrylonitrile)//(polyaniline/polyvinyl pyrrolidone) (denoted [PAN]//[PANI/PVP]) Janus nanofibers (NFs). This peculiar Janus structure can collect and output voltage by conductive paths based on the Wheatstone bridge principle. Moreover, owing to the nanoscale asymmetric geometry for efficient polarization and induced charges collection, the Janus NFs show superior piezoelectric properties. As a result, flexible (PAN)//(PANI/PVP) Janus nanofibers integrated membrane (JNFIM) dispensing with two flat electrodes can directly output a high voltage of 2 V under a tiny force of 1 N. Furthermore, the JNFIM enables to detect pressures with extra‐high linear sensitivity (1.88 V N−1) and low detection limit (0.1 N). Thus, our work provides a simple route for the development of nanoscale, low‐cost, and high‐sensitivity integrated materials for pressure sensing, revealing promising applications in miniature robotics and wearable devices.

Evaluation of Collaborative Robot Sustainable Integration in Manufacturing Assembly by Using Process Time Savings.

Collaborative robots are enablers of flexibility in the current dynamic and uncertain manufacturing environment. Decision making on its implementation requires technical feasibility, involving productivity and workforce implications that should be faced in an integrated perspective in processes where many components of different materials are assembled in products of increasing diversity and complexity. This study introduces two new parametric models for collaborative robotics, formulated in order to evaluate the differential cost of assembly (economic dimension) and the differential income from taxes that supports short-term workforce displacement (social dimension) in cobot implementation. Updated techno-economical parameters are selected for assessing feasibility ranges of application in different production scenarios. Next, the influence curves of productivity gain for a feasible implementation of cobot establish thresholds for decision making under both criteria. The results show the need for productivity gains that are significantly lower in high-wage scenarios than in low-wage scenarios; however, in a joint approach, breakeven productivity gain is always higher for the social dimension threshold than for the economic requirement of cost-effective manufacturing, with a higher gap in low-wage cases. The detailed analysis of a real case study of cobot implementation for assembly demonstrates the practical application of models and potential for future research.

Experimental studies of a high-gradient X-band welded hard-copper split accelerating structure

Recent research on high-gradient radio frequency (RF) accelerating structures indicates that the use of hard copper alloys provides improvement in high gradient performance over annealed copper. Such structures are made by bonding individually manufactured parts. However, there are no well-established bonding techniques that preserve the hardness, surface finish and cleanliness required for high gradient operation. To preserve the copper hardness, RadiaBeam has developed a novel high-gradient split accelerating structure, based on electron beam welding joining technique. This technique provides efficient bonding with strong, clean welds and minimal thermal loading, while maintaining a clean inner RF environment. Our RF design and fabrication methodology limits the small heat affected zone to the outer cavity envelop, with virtually no distortions or thermal loading of critical RF surfaces. It also incorporates provisions to precisely control the gap despite conventional issues with weld joint shrinkage. To date we have manufactured and validated an RF accelerating structure joined by electron-beam welding that incorporates a novel open split design to significantly reduce the assembly complexity and cost. In this paper, we will present the electromagnetic design of this structure, discuss bonding, and present the results of high-power tests, where the accelerating gradients of 140 MV m−1 with surface peak fields of 400 MV m−1 were achieved for flat-top pulse length of 600 ns with an RF breakdown rate of 10−4 1/(pulseċm).

DESAIN PROSES MANUFAKTUR PADA PERANCANGAN ULANG PRODUK MEJA MAKAN

The objective of this research is to analyze the potential efficiency of the production process due to the redesign of the dining table product. The research methodology uses desain for manufacturing (DFM) technique which is divided into three stages: (1) analysis of the production cost of the parts of a folding dining table, (2) analysis of the decrease in a folding dining table's production cost, and (3) analysis of the production efficiency of the impact of folding dining table product development. Based on the results of data processing and analysis, it is concluded that the elements of the production cost of folding dining table products consist of variable costs, fixed costs, and overhead costs. Variable costs consist of the cost of raw materials and additional materials used. Fixed costs consist of depreciation costs or depreciation of the machines used and labor costs and the last is overhead costs which consist of electricity costs. The implementation of DFM in the redesign of the dining table product shows a decrease in component costs by 14,9% and reduction in assembly costs by 33,3% due to a reduction in the number of components. Changes in the type and amount of raw materials lead to time efficiency in the assembly and material handling processes because it is lighter. The addition of the function of the dining table into a folding dining table that can be used as a mirror increases the performance of the dining table product.