Conventional Production Line Research Articles

Computational modelling of extrusion process temperatures on the interactions between black soldier fly larvae protein and corn flour starch

Insects such as the black soldier fly (BSF) are recently being studied as food sources to address concerns about how to meet the food demand of the growing world population, as conventional production lines for meat proteins are currently unsustainable sources. Studies have been conducted evaluating the use of insect proteins to produce extruded foods such as expanded snacks and meat analogues. However, this field of study is still quite new and not much has been studied beyond digestibility and growth performance. The purpose of this work was to evaluate the compatibility of protein extracted from BSF flour with corn flour starch within an extruded balanced shrimp feed model through molecular dynamics simulations, for which cohesive energy density and solubility parameter (δ) of both components were determined. The calculations’ results for the protein molecule systems yielded an average δ of 14.961 MPa0.5, while the δ for starch was calculated to be 23.166 MPa0.5. The range of difference between both δ (10 > δ > 7) suggests that the interaction of the BSF protein with corn starch is of a semi-miscible nature. These results suggest that it is possible to obtain a stable starch-protein mixture through the extrusion process.

Short-process preparation of grain-oriented electrical steel

The conventional production line of grain-oriented electrical steel (GOES) is long and the columnar grains in the cast slabs have adverse effects on GOES. In this paper, the short preparation process for GOES using top side-pouring twin-roll strip casting (TSTRC) was investigated. The results show that TSTRC can prepare cast strips with equiaxed grains. Conventional slab reheating, hot rolling, and normalization can be eliminated. The origin of Goss grains and the preparation of inhibitors were studied.

Strategic Production Process Design With Additive Manufacturing in a Make-to-Stock Environment

Abstract With the development and gradual maturity of additive manufacturing (AM) over the years, AM has reached a stage where implementation into a conventional production system becomes possible. With AM suitable for small volumes of highly customized production, there are various ways of implementing AM in a conventional production line. The aim of this paper is to present a strategic design approach to implementing AM with conventional manufacturing in a complementary manner for parallel processing of production orders of large quantities in a make-to-stock environment. By assuming that a single machine in conventional manufacturing can be operated using AM, splitting of production orders is allowed. Therefore, production can be conducted by both conventional and AM processes simultaneously, with the latter being able to produce various make-to-stock parts in a single build. A genetic algorithm with a scheduling and rule-based heuristic for part allocation on the build plate of AM process is used to solve a multi-objective implementation problem of AM with conventional manufacturing, with cost, scheduling, and sustainability being the considered performance measures. By obtaining a knee-point solution using varying numbers of population size and generation number, an experiment involving an industry case study of implementing the fused deposition modeling (FDM) process with injection molding process shows the greatest impact, i.e., increase, in cost. Except for material efficiency, improvements are shown in scheduling and carbon footprint objectives.

Features of cotton and viscose vortex yarns directly spun from card slivers

In this study, the possibility of manufacturing vortex yarns directly from card slivers having two different sliver counts is investigated. The fiber type, card sliver count, and yarn count are considered as the selected parameters to be examined due to their effects on unevenness, yarn imperfections, hairiness, breaking strength, and elongation properties. For this purpose, cotton and viscose yarns in three yarn counts, 14.77, 19.69, and 29.53 tex, were produced from two card sliver counts (3.58 and 4.92 ktex) by a Murata Vortex Spinning (MVS) system. The study revealed that vortex yarns can be produced by feeding directly card slivers to the MVS system, and resulting yarns have features compatible with those yarns produced on a conventional production line. In the context of this study, where the drafting process is eliminated, it is recommended to produce yarns from fine card slivers to reach a lower CVm% and imperfection value and to produce yarns by coarser card slivers to reach lower hairiness and higher Rkm values.

Forecasting the steelmaking and casting of a medium manganese steel

The steelmaking and casting of medium Mn steels brings some challenges in the production route because of their high alloying content. In this paper, the evaluation of the casting processes for these steel chemistries is assessed with a set of models and laboratory-scale tests, in order to find possible casting conditions. Results evaluation from this study pointed out to the regular conventional slab casting and hot rolling route, so that it can be produced through a conventional production line.

Simulation-based evaluation of performance benefits from flexibility in assembly systems and matrix production

This paper contributes to a novel approach for analysing and quantifying the benefits for reconfigurable cellular manufacturing and assembly systems (RCMS/RCAS), also known as Matrix production, based on modelling and dynamic simulation.International market trends concerning consumer behaviour and demand result in increasing flexibility requirements, which conventional production lines struggle to meet, thus creating the need for flexible production and assembly systems such as Matrix production. The flexibility results in additional variables and thus a more complex system behaviour. To utilize its benefits, the design and setup of a matrix production is crucial and for potential real-world applications. However, methods to quantitatively assess beneficial features of a matrix production are only beginning to appear in the literature, making decision-making for a production system transformation challenging. This paper contributes a simulation-based approach to analyse the performance benefits of matrix production using modelling and dynamic simulation. The method is demonstrated with a simplified automotive assembly use case for a dynamic multi-variant production. The results confirm the feasibility of the method and quantify the potential for increased assembly system performance gained from specific flexibility features in a matrix production.

A Formal Approach to Requirements Engineering of Automated Systems: Facing the Challenge for New Automated Systems

It is a consensus that intelligent manufacturing plants should be automated, especially in what concerns automated processes to Industry 4.0. This new manufacturing approach is based on multifunctional distributed systems that, for its turn, depend on a sound design requirements phase. Consequently, the requirement specifications became even more significant in the design of intelligent manufacturing systems, where the possibility to analyze requirements previously could save time and effort. Frequently, relevant requirements assumptions change during the engineering process due to emergent and volatile requirements—called “scope creep.” A revision of the requirements approach should be demanding to minimize this problem. The proposal presented in this work anticipates the formal representation of automated systems requirements to allow the proper analysis and validation. Also, since conventional production lines have been replaced by a product-service (production) systems (PSS), there is pressure to review the requirements phase, mainly to automated systems. To increase the accuracy, we propose a requirements cycle composed of modeling, analysis, and (formal) verification where formalization is anticipated by capturing visual modeled requirements. Alternative approaches to the functional method are also explored, considering the Goal-oriented Requirements Engineering approach, the best fit to PSS. A formal process to treat requirements in a functional approach, represented by UML diagrams, is transferred to Petri Nets and submitted to formal analysis. Traditional translation from UML to Petri Nets is replaced by an object-oriented match to Petri Nets extensions covered by the standard ISO/IEC 15.909. A comparison between this approach and the goal-oriented raises a discussion about the requirements efficiency dilemma, where functionality could be pointed as the main reason to scope creep. Therefore, a strictly functional approach is proposed with a new transference algorithm, and the results are used to support the discussion about using goal-oriented alternatives. A case study of the chemical industry illustrates the practical use of the proposal.

UMG silicon for solar PV: From defects detection to PV module degradation

Upgraded metallurgical grade silicon (UMG-Si) for photovoltaic (PV) solar applications has been manufactured through the metallurgical route by means of the process developed by Ferrosolar. In an ambitious mass production test, performed in commercial solar cells and modules production lines, the silicon was proven to be appropriate for photovoltaics applications (Forniés et al., 2019 Mass production test of solar cells and modules made of 100% umg silicon. 20.76% record efficiency. Energies 12), reaching, in a conventional production line, up to 20.76% of solar cell efficiency with multicrystalline cells made of 100% UMG silicon. In this paper we present more results from the mentioned massive test. Defect engineering is being applied to improve the bulk lifetime of the UMG wafers and to guide in the identification of the limiting defects in the material. Moreover, the modules produced with 100% UMG silicon solar cells were installed together with the modules produced in the same production line with polysilicon material to assess the degradation of the UMG silicon when compared to polysilicon. After 24 months of outdoor PV generation, the degradation, in terms of Performance Ratio at 25 °C (25PR) diminution, has been the same for both types of modules. Additionally, a Life Cycle Assessment (LCA) has been performed for this UMG silicon and state-of-the-art Siemens polysilicon to compare the environmental impact of both silicon feedstocks. The results presented in this paper; chemical analysis of wafers, defect engineering, low degradation, average efficiency and environmental assessment, lead to a complete study of UMG silicon, confirming its potential to be used as raw material for PV applications.

The Role of 3D Printing in the Fight Against Covid-19 Outbreak

Along with the COVID-19 pandemic, urgent needs for medical and specialized products, especially personal protective equipment, has been overwhelming. The conventional production line of medical devices has been challenged by excessive global demand, and the need for an easy, low-cost and rapid fabrication method is felt more than ever. In a scramble to address this shortfall, manufacturers referred to additive manufacturing or 3D printing to fill the gap and increase the production line of medical devices. Various previously/conventionally fabricated designs have been modified and redesigned to suit the 3D printing requirement to fight against COVID-19. In this perspective, various designs accommodated for the current worldwide outbreak of COVID-19 are discussed and how 3D printing could help the global community against the current and future conditions has been explored.

Study of Nano Texturing on Multi-crystalline Silicon Solar Cells

Nano texturing has been confirmed as an effective structure to improve the efficiency of multi-crystalline silicon solar cells by reducing optical loss. In this study, nano textured solar cells are fabricated by the Reactive Ion Etching (RIE) method based on a conventional production line. Several characterization methods are employed to evaluate the morphology, minority carrier lifetime, quantum efficiency and electricity performance of both nano textured and micro textured solar cells. The results show that nano textured solar cell has the highest efficiency of 19.21 % and an average efficiency of 18.86%, which is 0.57 % higher than that of micro textured solar cells. Thus, the RIE method is an effective way to manufacture nano textured solar cells. It can demonstrably improve the photoelectric conversion efficiency of mass-produced solar cells and reduce the production cost, which is significant to the development of solar cell industry.

Mass Production Test of Solar Cells and Modules Made of 100% UMG Silicon. 20.76% Record Efficiency

For more than 15 years FerroAtlantica (now Ferroglobe) has been developing a method of silicon purification to obtain Upgraded Metallurgical Grade Silicon (UMG-Si) for PV solar application without blending. After many improvements and optimizations, the final process has clearly demonstrated its validity in terms of quality and costs. In this paper the authors present new results stemming from a first mass-production campaign and a detailed description of the purification process that results in the tested UMG-Si. The subsequent steps in the value chain for the wafer, cell and module manufacturing are also described. Two independent companies, among the Tier-1 solar cells producers, were selected for the industrial test, each using a different solar cell technology: Al-BSF and black silicon + PERC. Cells and modules were manufactured in conventional production lines and their performances compared to those obtained with standard polysilicon wafers produced in the same lines and periods. Thus, for Al-BSF technology, the average efficiency of solar cells obtained with UMG-Si was (18.4 ± 0.4)% compared to 18.49% obtained with polysilicon-made wafers. In the case of black silicon + PERC, the average efficiency obtained with UMG-Si was (20.1 ± 0.6)%, compared to 20.41% for polysilicon multicrystalline wafers.

Influence of Different Production Systems on the Quality and Shelf Life of Poultry Meat: A Case Study in the German Sector

Production-specific factors, such as breeding, diet, and stress, are known to influence meat quality, but the effect of different husbandry systems on the development of quality parameters and shelf life has hardly been investigated. Thus, the aim of the study was the investigation of an alternative production system based on a slow-growing, corn-fed, and antibiotics-free chicken line compared with conventional poultry production. Additionally, the effect on meat quality, microbiology, and spoilage was analyzed. In total, 221 breast filets from a German poultry meat producer were investigated. Nutritional, biochemical, and cooking loss analyses were conducted on a subset of samples 24 h after storage. The rest of the samples were stored aerobically at 4°C, and the spoilage process was characterized by investigating pH, color, lipid oxidation, microbiology, and sensory attributes subsequently every two days during storage. The alternative production line showed a significantly healthier nutritional profile with a higher protein and lower fat content. Additionally, the amount of L-lactic acid and D-glucose was significantly higher than in the conventional production line. The color values differed between both production lines, with the corn-fed line displaying more yellowish filets. The lipid oxidation and microbial spoilage were not affected by the production line. The shelf life did not differ between the investigation groups and was deemed 7 days in both cases. Despite the highest severity of white striping being observed most in the conventional production line, there was no overall difference in the incidence among groups. The purchase decision was affected by the occurrence of white striping and showed a tendency for a higher acceptance for the alternative production line.

Thin Multicrystalline Silicon Solar Cells With High Mechanical Strength and Less Light-Induced Degradation

Cost reduction and efficiency promotion are well-known development directions faced by the photovoltaic industry, and the thin Si solar cell has been identified as a potential candidate to conquer the field. In this article, 120- μ m-thick p-type thin multicrystalline silicon (mc-Si) solar cells with a structure based on a full Al back surface field and an efficiency comparable to 180- μ m-thick solar cells were fabricated using a conventional production line. The mechanical strength and light-induced degradation effect for the 120- μ m-thick mc-Si solar cells were investigated. Our study shows that 120- μ m-thick mc-Si cells have greater mechanical strength with a bending displacement of 15.87 mm compared with 180- μ m-thick solar cells (7.87 mm), which can facilitate the development of advanced flexible solar cell modules. An important finding of this work is that thin mc-Si solar cells show a weaker light-induced degradation (LID) effect than 180- μ m-thick solar cells. A ∼ 2.7% (relative) degradation in efficiency ( η ) was observed for the 120- μ m-thick thin mc-Si solar cells following a one month exposure test. A thin Si solar cell with a promising new type of structure may also be expected to achieve a high η , a low LID effect, and a flexible capability in the near future.

Application of Nano Texturing on Multi-Crystalline Silicon Solar Cells

Nano texturing has been confirmed as an effective structure to improve the efficiency of multi-crystalline silicon solar cells by reducing optical loss. In this study, nano textured solar cells are fabricated by the Reactive Ion Etching (RIE) method based on a conventional production line. Several characterization methods are employed to evaluate the morphology, minority carrier lifetime, quantum efficiency and electricity performance of both nano textured and micro textured solar cells. The results show that nano textured solar cells have a maxiumum efficiency of 19.21 % and an average efficiency that is 0.57 % higher than that of micro textured solar cells. Thus, the RIE method is an effective way to manufacture nano textured solar cells. It can demonstrably improve the photoelectric conversion efficiency of mass-produced solar cells and reduce the production cost, which is significant to the development of solar cell industy. DOI: http://dx.doi.org/10.5755/j01.ms.24.2.17398

0.02%Nb空冷仿晶界型铁素体/粒状贝氏体复相钢的相变及强韧性

In order to produce Mn-series low carbon steels using alloying elements with low cost and following the conventional production line without controlled cooling facilities and not need- ing special heat-treatment, Mn-series low carbon air cooling grain boundary allotriomorphic ferrite (FGBA)/granular bainite (BG) steels, alloying with Si-Mn-Cr, have been developed. The effect of 0.02%Nb on the phase transformation and strength-toughness of a FGBA/BG steel have been inves- tigated by using Gleeble-1500D machine and hot rolling test in this paper. Two specimens with and without Nb addition were deformed by 21% at 850 and then air cooling to room temperature. For Nb free steel, the average size of FGBA is 25 µm in length and 10 µm in width. The average size of intragranular ferrite is about 6—8 µm. For FGBA/BG steel with 0.02%Nb, the average size of FGBA is 10 µm in length and 4 µm in width. The average size of intragranular ferrite is less than 4 µm. Compared with Nb free steel, the size of bainitic ferrite and martensite/austenite (M-A) island de- crease and their corresponding volume fractions increase in the FGBA/BG steel with 0.02%Nb. The experimental results indicate that the addition of 0.02%Nb increases the hardenability of the FGBA/BG steel, suppresses the transformation of ! �, refines the size of grain boundary allotriomorphic ferrite, promotes the granular bainitic transformation, lowers the bainitic start temperature (Bs), and refines the granular bainite including its bainitic ferrite and M-A islands. It is suggested that the effects of

Charging control on high energy implanters: A process requirement demonstrated by plasma damage monitoring

Charging phenomena is one of the main problems faced in ion implantation. Anti-charging system such as plasma flood gun (PFG) are currently running on high current and medium current implanters to reduce potential charging damage on device structures. However, in a conventional production line, high energy implantation steps are still often used without any charge compensation technique. Faced with micro-arcing defects detected after Well implantation steps on production lots, we have clearly demonstrated that the defectivity issue was eradicated by enabling the PFG system on the VIISta3000 high energy implanter. In addition we have investigated charging as a function of PFG properties by plasma damage monitoring (PDM) and proved that voltages developed on oxidized wafers processed on the VIISta3000 were not insignificant.

A Custom-Made Transfer Machine for the Manufacturing of Luxury Brass Hinges

The design and fabrication of an automatic transfer machine for manufacturing solid brass hinges is described. This machine is intended to replace a conventional production line increasing the productivity at least threefold. In addition product quality is substantially improved. The machine sequencing is done by a PLC. Speed Control at the critical stations is achieved by incorporating damping systems. Machining tolerance, cutting parameters and speed control showed to be the critical issues.