Insertion Machine Research Articles

Dynamic Analysis of Continuous Pin Insertion Machines and Their Application in Precision Connector Manufacturing

Dynamic Analysis of Continuous Pin Insertion Machines and Their Application in Precision Connector Manufacturing

Design and Test of Automatic Feeding Device for Shed Pole of Small-Arched Insertion Machine

Design and Test of Automatic Feeding Device for Shed Pole of Small-Arched Insertion Machine

Design and Parameter Optimization of Rotary Double-Insertion Device for Small Arched Insertion Machine

China’s small arched shed-building machinery suffers from a low degree of mechanization, building efficiency, and qualification rate for frame insertion. Therefore, we designed a rotary double-insertion device and established the equation for its motion trajectory. The analysis shows that in the rotary insertion process, a better point of entry into the soil exists. A simulation model was constructed in ADAMS, and the static and dynamic trajectories were analyzed. Additionally, the optimal planting and insertion speed ratios were determined. Considering the qualified rate of the insertion frame as the evaluation index to establish a regression model, we adopted a three-factor three-level experimental design and established the planting speed ratio, center distance of the planting arm, and length of the pressing rod arm as the main influencing factors. We used Design-Expert 13 to perform the analysis of variance and determined the optimal parameter combinations. The experimental results show that the planting speed ratio was 0.7, the center distance of the planting arm group was 554 mm, the length of the pressing rod arm was 923 mm, and the qualification rate of trellis planting at this time was 98.05%. The bench was adjusted and tested based on the optimal parameter combination. The average value of the measured trellis qualification rate was 96.73%, and the relative error between the test value and the theoretical optimization value was 1.32%, thereby verifying the reliability of the optimal parameter combination. Field verification test results show that the rotary double-insertion device had a planting speed ratio of 0.7 and a trellis qualified rate of 95.74% compared with the theoretical optimization value of 2.31%. Conforming to the design requirements of small arch shed-building machinery, the prototype operation performance was stable.

Bin-Picking Solution for Randomly Placed Automotive Connectors Based on Machine Learning Techniques

This paper presents the development of a bin-picking solution based on low-cost vision systems for the manipulation of automotive electrical connectors using machine learning techniques. The automotive sector has always been in a state of constant growth and change, which also implies constant challenges in the wire harnesses sector, and the emerging growth of electric cars is proof of this and represents a challenge for the industry. Traditionally, this sector is based on strong human work manufacturing and the need arises to make the digital transition, supported in the context of Industry 4.0, allowing the automation of processes and freeing operators for other activities with more added value. Depending on the car model and its feature packs, a connector can interface with a different number of wires, but the connector holes are the same. Holes not connected with wires need to be sealed, mainly to guarantee the tightness of the cable. Seals are inserted manually or, more recently, through robotic stations. Due to the huge variety of references and connector configurations, layout errors sometimes occur during seal insertion due to changed references or problems with the seal insertion machine. Consequently, faulty connectors are dumped into boxes, piling up different types of references. These connectors are not trash and need to be reused. This article proposes a bin-picking solution for classification, selection and separation, using a two-finger gripper, of these connectors for reuse in a new operation of removal and insertion of seals. Connectors are identified through a 3D vision system, consisting of an Intel RealSense camera for object depth information and the YOLOv5 algorithm for object classification. The advantage of this approach over other solutions is the ability to accurately detect and grasp small objects through a low-cost 3D camera even when the image resolution is low, benefiting from the power of machine learning algorithms.

Local heat generation during screw insertion into diaphyseal bone: a biomechanical study on different conditions (e.g. screw type, material, mode of insertion)

BackgroundThe implantation of screws is a standard procedure in musculoskeletal surgery. Heat can induce thermal osteonecrosis, damage the bone and lead to secondary problems like implant loosening and secondary fractures. The aim of this study was to investigate whether screw insertion generates temperatures that can cause osteonecrosis.MethodsWe measured the temperature of twenty human femur diaphysis in a total of 120 measurements, while screws of different material (stainless steel and titanium alloy) and different design (locking and cortex screw) were inserted in three different screwing modes (manual vs. machine screwing at full and reduced rotational speed) with 6 thermocouples (3 cis and 3 trans cortex). Each was placed at a depth of 2 mm with a distance of 1.5 mm from the outer surface of the screw.ResultsThe screw design (cortical > locking), the site of measurement (trans-cortex > cis-cortex) and the type of screw insertion (hand insertion > machine insertion) have an influence on the increase in bone temperature. The screw material (steel > titanium), the site of measurement (trans-cortex > cis-cortex) and the type of screw insertion (machine insertion > hand insertion) have an influence on the time needed to cool below critical temperature values. The combination of the two parameters (maximum temperature and cooling time), which is particularly critical for osteonecrosis, is found only at the trans-cortex.ConclusionInserting a screw hast the potential to increase the temperature of the surrounding bone tissue above critical values and therefore can induce osteonecrosis. The trans-cortex is the critical area for the development of temperatures above the osteonecrosis threshold, making effective cooling by irrigation difficult. It would be conceivable to cool the borehole with cold saline solution before inserting the screw or to cool the screw in cold saline solution. If possible, insertion by hand should be considered.

Design and Fabrication of Automatic Fuse Insertion Machine

Fireworks are a class of low explosive pyrotechnic devices used for aesthetic and entertainment purposes. In our project, we automate the fuse insertion process of the Chinese cracker (Bhijili). In India, the fuse insertion is done by handmade process. Due to handmade process, it creates serious health problems to the labours and it requires more labour, consumes more time. So, we planned to implement this process in a “PLC based automatic machine”. In which we combined Piercing, Dipping and Fuse Insertion. In reference of cracker manufacturing in China, they already had automatic fuse insertion, but they have a different procedure (chemical filling is done after the fuse insertion) compared to our country’s procedure, fuse is inserted after chemical filling. In our automation, we sequence the process of piercing and fuse insertion in an automatic manner. Advantage of our project are, increases productivity, reduced lead time, elimination of setup time, reduce the cost, fewer accident. For an emergency safety to the human and the surroundings, we use the fireball (mono ammonium phosphate) for the occasional fire accident which reduces the concentration of the blast in a few seconds.

Cellular Solid-State NMR Applied to Bacterial and Human cells

Solid-state NMR (ssNMR) is a method that can be applied to gain atomic-level insight into heterogeneous molecular systems. Over the last 15 years, ssNMR has seen strong methodological and instrumental developments that have allowed for the characterization of complex molecules including membrane proteins, amyloid fibrils or protein biopolymers with remarkable structural accuracy and comprehensiveness. More recently, ssNMR has profited from revolutionary enhancements in sensitivity, mainly due to the advent of Dynamic Nuclear Polarization (DNP) and it has seen significant progress in the field of ssNMR 1H detection. In our contribution we show how to make combined use of such methods to probe biomolecules in bacterial and human cells. Applications include protein translocation and insertion machines in bacteria and extend to membrane associated as well as soluble protein complexes in human cells. We also describe how to combine such ssNMR-based studies with modalities such as cryo-electron tomography (CET) and Fluorescence microscopy to obtain structural insight into cell organization from the atomic to sub-micrometer scale.

Robotic assembly planning and control with enhanced adaptability through function blocks

Manufacturing companies today need to maintain a high level of flexibility and adaptability to deal with uncertainties on dynamic shop floors, including, e.g. cutting tool shortage, part supply interruption, urgent job insertion or delay and machine unavailability. Such uncertainties are characteristic in component assembly operations. Addressing the problem, we propose a new method using function blocks to achieve much improved adaptability in assembly planning and robot control. In this paper, we propose to use event-driven function blocks for robotic assembly, aiming to plan trajectory and execute assembly tasks in real time. It is envisioned that this approach will achieve better adaptability if applied to real-world applications.

Theory of interaction, insertion modeling, and cognitive architectures

Abstract The paper presents a new cognitive architecture based on insertion modeling, one of the paradigms of a general theory of interaction, and a basis for multiagent system development. Insertion cognitive architecture is represented as a multilevel insertion machine which realizes itself as a high-level insertion environment. It has a center to evaluate the success of its behavior, which is a special type agent that can observe the interaction of a system with external environment. The main goal of a system is achieving maximum success repeated. Considered as an agent this machine is inserted into its external environment and has the means to interact with it. The internal environment of intelligent cognitive agent creates and develops its own model and the model of external environment. If the external environment contains other agents, they can be modeled by internal environment, which creates corresponding machines and interprets those machines using corresponding drivers, comparing the behaviors of models and external agents. Insertion architecture is now under development on the base of Insertion modeling system, developed in Glushkov Institute of Cybernetics. The nearest application will be the cognitive intellectual agent for software understanding.

A case of nosocomial Legionella pneumonia associated with a contaminated hospital cooling tower

We report the epidemiological investigation of a nosocomial pneumonia case due to Legionella pneumophila linked to a contaminated hospital cooling tower in an immune-compromised patient. A 73-year-old female patient was diagnosed with nosocomial Legionella pneumonia proven by a culture of L.pneumophila serogroup 1 from bronchoalveolar lavage fluid. Two strains isolated from the patient and two strains isolated from two cooling towers were found to be identical using repetitive-sequence-based-PCR with a 95% probability. This Legionella pneumonia case might be caused by aerosol from cooling towers on the roof of the hospital building which was contaminated by L.pneumophila. We increased up the temperature of hot water supply appropriately for prevention of Legionella breeding in an environment of patients' living. On the other hand, as the maintenance of cooling tower, we increased the frequency of Legionella culture tests from twice a year to three times a year. In addition, we introduced an automated disinfectants insertion machine and added one antiseptic reagent (BALSTER ST-40 N, Tohzai Chemical Industry Co., Ltd., Kawasaki, Japan) after this Legionella disease, and thereafter, we have no additional cases of Legionella disease or detection of Legionella spp. from the cooling tower or hot water supply. This case demonstrates the importance of detecting the infection source and carrying out environmental maintenance in cooperation with the infection control team.

The Parametric Simulation Design Method of Conjugate Cams of Automatic Pin Insertion Machine Based on Creo Parametric Software

Cam mechanisms are widely used in automated machines. Conjugate cams have become popular for its eminent kinematics and dynamic performance in research and in industry. As a commonly used cam mechanism in industry, especially in automatic pin insertion machines, conjugate cams have the advantages of being highly efficient, highly accurate and relatively cheap. A parametric simulation method was used to create a conjugate cam profile. This paper describes the steps used to create 3D models of the conjugate cam and the basic principles used to simulate the motion of cam mechanisms. The motion simulations were done with the parametric 3D modeling method using Creo Parametric Software.

A Randomized Comparative Crossover Study to Assess the Affect on Circuit Life of Varying Pre-Dilution Volume Associated with CVVH and CVVHDF

To determine if circuit life is influenced by a higher pre-dilution volume used in CVVH when compared with a lower pre-dilution volume approach in CVVHDF. A comparative crossover study. Cases were randomized to receive either CVVH or CVVHDF followed by the alternative treatment. All patients >or= 18 yrs of age who required CRRT while in ICU were eligible to participate, but excluded if coagulopathic, thrombocytopenic or unable to receive heparin. Based on an intention-to-treat, 45 patients were randomized to receive either CVVH or CVVHDF followed by the alternative treatment. A 24-bed, tertiary, medical and surgical adult intensive care unit (ICU). Blood flow rate, vascular access device and insertion site, hemofilter, anticoagulation and machine hardware were standardized. An ultrafiltrate dose of 35 ml/ kg/h delivered pre-filter was used for CVVH. A fixed pre-dilution volume of 600 mls/h with a dialysate dose of 1 L was used for CVVHDF. Thirty-one patients received CVVH or CVVHDF out of 45 participants followed by the alternative technique. There was a significant increase in circuit life in favor of CVVHDF (median=16 h 5 min, range=40 h 23 min) compared with CVVH (median=6 h 35 min, range=30 h 45 min). A Mann-Whitney U test was performed to compare circuit life between the two different CRRT modes (Z=-3.478, p<0.001). Measurements of circuit life on the 93 circuits which survived to clotting (50 CVVH and 43 CVVHDF) were log transformed prior to under taking a standard multiple regression analysis. None of the independent variables - activated prothrombin time (aPTT), platelet count, heparin dose, patient hematocrit or urea - had a coefficient partial correlation >0.09 (coefficient of the determination=0.117) or a linear relationship which could be associated with circuit life (p=0.228). Pre-diluted CVVHDF appeared to have a longer circuit life when compared to high volume pre-diluted CVVH. The choice of CRRT mode may be an important independent determinant of circuit life.

Heuristic approaches for batching jobs in printed circuit board assembly

The goal of the printed circuit board job-batching problem is to minimize the total manufacturing time required to process a set of printed circuit board jobs on an insertion machine. We have developed four families of heuristics to solve this problem: the clustering family, the bin-packing family, a family of sequencing genetic algorithms, and a grouping genetic algorithm. Within each family of heuristics, we developed several variations. Some of the variations use techniques from the literature and some of the techniques we developed specifically for this problem. We test the variations and select a good performer from each family.

A genetic algorithm for sequential part assignment for PCB assembly

We present a genetic algorithm for printed circuit board (PCB) assembly, which simultaneously solves the feeder assignment and component sequencing problems. The algorithm uses a unique gene selection procedure that increases the convergence rate without degrading the solution quality. We have compared the performance of our algorithm with existing approaches and have demonstrated improved performance. We have also implemented the algorithm on a Quad IIIc insertion machine for surface mount components. The resulting suboptimal assembly times estimated by the algorithm have been found to be close to the actual optimal values.

Cost minimization and workload balancing in printed circuit board assembly

We consider an operation assignment problem arising from a Printed Circuit (PC) board assembly process. The research was inspired by applications at Hewlett-Packard Company where hundreds of types of PC boards require the insertion of thousands of types of components. The components can be inserted manually or by automated insertion machines. The machines can only hold a limited number of different component types. We investigate how to assign the boards and components to the machines and manual process so as to minimize cost while at the same time balancing machine workloads. We first present a Binary Integer Program (BIP) formulation of the problem. We then develop optimality results that allow us to reduce significantly the size of the BIP. Using the improved BIP formulation, and upper bounds generated using a Cost Minimizing Workload Balancing (CMWB) heuristic that we develop, we show how branch-and-bound can be used to find optimal solutions to small and medium-sized problems in reasonable time. We also show that the CMWB heuristic finds solutions in seconds of CPU time that are within a few percent of optimal. In addition, the CMWB heuristic outperforms the heuristic that has been used at Hewlett-Packard, as well as the longest expected processing time heuristic. Although this paper specifically addresses a problem of partially-automated PC board assembly, the results apply to a more general set of problems, including job and tool assignment in flexible manufacturing systems, and general operation assignment problems.

Cost minimization and workload balancing in printed circuit board assembly

We consider an operation assignment problem arising from a Printed Circuit (PC) board assembly process. The research was inspired by applications at Hewlett-Packard Company where hundreds of types of PC boards require the insertion of thousands of types of components. The components can be inserted manually or by automated insertion machines. The machines can only hold a limited number of different component types. We investigate how to assign the boards and components to the machines and manual process so as to minimize cost while at the same time balancing machine workloads. We first present a Binary Integer Program (BIP) formulation of the problem. We then develop optimality results that allow us to reduce significantly the size of the BIP. Using the improved BIP formulation, and upper bounds generated using a Cost Minimizing Workload Balancing (CMWB) heuristic that we develop, we show how branch-and-bound can be used to find optimal solutions to small and medium-sized problems in reasonable time. We also show that the CMWB heuristic finds solutions in seconds of CPU time that are within a few percent of optimal. In addition, the CMWB heuristic outperforms the heuristic that has been used at Hewlett-Packard, as well as the longest expected processing time heuristic. Although this paper specifically addresses a problem of partially-automated PC board assembly, the results apply to a more general set of problems, including job and tool assignment in flexible manufacturing systems, and general operation assignment problems.

Design and validation of a machine for reproducible precision insertion of femoral hip prostheses for preclinical testing.

Preclinical testing of orthopaedic implants is becoming increasingly important to eliminate inferior designs before animal experiments or clinical trials are begun. Preclinical tests can include both laboratory bench tests and computational modeling. One problem with bench tests is that variability in prosthesis insertion can significantly influence the failure rate; this makes comparison of prostheses more difficult. To solve this problem an insertion method is required that is both accurate and reproducible. In this work, a general approach to the insertion of hip prostheses into femoral bones is proposed based on physically replicating an insertion path determined using computer animation. As a first step, the seated prosthesis position is determined from templates and femur radiographs. Three-dimensional images of the prosthesis and bone are then imported into computer animation software and an insertion path in the coronal plane is determined. The insertion path is used to determine the profile of a cam. By attaching the prosthesis to a carriage, which is pneumatically moved along this cam, the required insertion motion of the prosthesis in the coronal plane can be achieved. This paper describes the design and validation of the insertion machine. For the validation study, a nonsymmetric hip prosthesis design (Lubinus SPII, Waldemar Link, Germany) is used. It is shown that the insertion machine has sufficient accuracy and reproducibility for preclinical mechanical testing.

Autosplice to launch new, faster PCNC automatic interconnect insertion machine at Nepcon UK '99

Autosplice to launch new, faster PCNC automatic interconnect insertion machine at Nepcon UK '99

Optimal Component Assignment and Board Grouping in Printed Circuit Board Manufacturing

We consider operation assignment problems arising from a printed circuit board assembly process. The research was inspired by an application at Hewlett Packard where hundreds of types of printed circuit boards require the insertion of a number of components. The components can be inserted manually or by semiautomated insertion machines. The machines are limited in terms of the number of different component types that they can hold. We investigate how to assign the boards and components to the machines and manual process so as to minimize cost. An optimal solution technique is developed for the single-machine case and for the multiple-machine case where boards are not allowed to be set up on more than one process. In addition, a heuristic is developed which gives near-optimal solutions (within 0.3%) with much less computational effort. Although the problem this paper specifically addresses is that of partially automated PC board assembly, the results apply to a more general set of problems. Other applications include completely automated PC board assembly, flexible manufacturing systems, and general operation assignment problems.

A genetic algorithm approach to scheduling PCBs on a single machine

This paper addresses the problem of scheduling N printed circuit boards (PCBs) on a single machine equipped with an automatic component interchange mechanism. Assume that the total number of different components required to process all N PCBs is greater than the capacity of the spool. If the requisite components are not on the spool, then one or more component switches must occur before the PCB can be processed. The problem consists of finding the order to schedule the PCBs on the axial insertion machine and the components to place on the spool before each PCB is processed. The performance criterion is to minimize the total number of component switches. This problem is addressed employing a genetic algorithm to search the space of alternative solutions. To evaluate the performance of the GA, a heuristic solution based on a travelling salesman formulation is described. Extensive experiments were carried out for both approaches based on data extracted from industrial scenes.