Manufacturing Assembly Handbook

Manufacturing Assembly Handbook

1st Edition - September 20, 1989

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  • Author: Bruno Lotter
  • eBook ISBN: 9781483163383

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Manufacturing Assembly Handbook identifies the possibilities for the rationalization of assembly in relation to the production rate and the product design. This book is based on practical experience for practical application and will give experts in the field of rationalization guidelines for the solution of rationalization problems. Topics discussed in the text include the determination of the economic efficiency of assembly concepts, modules for the automation of assembly processes, design of assembly machines, and design of flexible-assembly systems. The integration of parts manufacturing processes into assembly equipment or of assembly operations into parts production equipment, planning and efficiency of automated assembly systems, and the operation of automated assembly systems are covered as well. Production engineers and managers and students of production technology will find the book very useful.

Table of Contents

  • Preface


    1. Introduction

    1.1 Assembly

    1.2 Status of Assembly in the Production Operation

    2. Product Design as a Requirement for Economic Assembly

    2.1 Product Design

    2.1.1 Base Part

    2.1.2 Number of Parts

    2.2 Assembly-Extended ABC Analysis

    2.2.1 Fundamental Question 1: Price of Individual Parts and their Manufacturing Costs

    2.2.2 Fundamental Question 2: Supply Condition

    2.2.3 Fundamental Question 3: Ease of Handling

    2.2.4 Fundamental Question 4: Assembly Direction and Ease of Assembly

    2.2.5 Fundamental Question 5: Assembly Methods

    2.2.6 Fundamental Question 6: Quality

    2.2.7 Fundamental Question 7: Assembly Costs

    2.2.8 Organizational Implementation of the Assembly-Extended ABC Analysis

    3. Manual Assembly

    3.1 Introduction

    3.2 Principles of Work-Point Arrangement

    3.3 Organizational Forms of Manual Assembly

    3.3.1 Single-Point Assembly

    3.3.2 Line Assembly

    4. Primary-Secondary Analysis - An Aid for the Determination of the Economic Efficiency of Assembly Concepts

    4.1 Introduction

    4.2 Definition of the Efficiency of Assembly Operations

    4.3 Field of Application

    4.3.1 Basic Analysis

    4.3.2 Fine Analysis of Single Assembly Work Points in Terms of Primary and Secondary Processes

    4.4 Application Example of Assembly Analysis by Primary and Secondary Activity

    4.4.1 Single Assembly Work Point with Provision of Parts in Manual Parts Dispensers

    4.4.2 Single Assembly Work Point with Parts Provision by a Parts Paternoster

    4.4.3 Single Assembly Work Point, Parts Provision Partly by Manual Parts Dispensers and Partly by Vibratory Spiral Conveyors

    4.4.4 Linking of Three Single Assembly Work Points to Form a Line Assembly with Manual Transfer of the Assembled Part

    4.4.5 Linking of Three Single Assembly Work Points to Form a Line Assembly with Mechanical Transfer of the Assembled Part in Workpiece Carriers

    4.4.6 Summary and Efficiency Consideration

    4.4.7 Primary-Secondary Fine Analysis for the Handling and Assembly of a Single Part

    4.5 Extended Analysis in Terms of Primary and Secondary Requirements for the Total Sequence of an Assembly Operation

    4.6 Practical Examples

    4.6.1 Example 1: Switch Assembly

    4.6.2 Example 2: Switch Element

    4.6.3 Example 3: Headlight Assembly

    5. Modules for the Automation of Assembly Processes

    5.1 Introduction

    5.1.1 Handling

    5.2 Feeder Units

    5.2.1 Feeder Units for Parts with One Arrangement Feature

    5.2.2 Feeder Units for Parts with Several Arrangement Criteria

    5.2.3 Electronic Position Identification of Parts

    5.2.4 The Feed of Interlocking Parts

    5.3 Handling Equipment

    5.3.1 Positioning Units

    5.3.2 Industrial Robots

    5.4 Transfer Equipment

    5.4.1 Cycled Transfer Equipment

    5.4.2 Non-Cycled Transfer Equipment

    5.5 Screw-Inserting Units

    5.6 Riveting Units

    5.6.1 Press-Riveting

    5.6.2 Rotating-Mandrel Riveting

    5.7 Welding Units

    5.7.1 Resistance Welding

    5.7.2 Laser Welding Equipment

    5.8 Soldering Equipment

    5.9 Bonding

    6. Design of Assembly Machines

    6.1 Introduction

    6.2 Single-Station Assembly Machines

    6.3 Multi-Station Assembly Machines

    6.3.1 Design of Parts Feed Stations

    6.3.2 Checking Stations

    6.3.3 Design of Pneumatically Operated Multi-Station Assembly Machines

    6.3.4 Design of Electric-Motor Driven Multi-Station Assembly Machines

    6.3.5 Assembly Machine Systems

    6.4 Combining Assembly Machines to Form Assembly Lines

    6.5 Integration of Manual Work Points in Automated Assembly Lines

    6.5.1 Manual Work Points for Parts Provision

    6.5.2 Manual Assembly Work Points

    6.6 Uncycled Assembly Lines Including Manual Work Points

    6.7 Availability of Assembly Systems

    6.7.1 Parameters of the Operational Characteristic

    6.7.2 Utilization

    6.7.3 Factors of Influence on the Availability of Assembly Systems

    6.7.4 Summary

    7. Design of Flexible-Assembly Systems

    7.1 Introduction

    7.2 Primary-Secondary Fine Analysis with the Application of Assembly Robots

    7.2.1 Reaching

    7.2.2 Gripping

    7.2.3 Collecting

    7.2.4 Assembly

    7.2.5 Release

    7.3 Working Space

    7.4 Gripper

    7.5 The Design of Flexible Single-Station Assembly Cells

    7.5.1 Semi-Automatic Flexible-Assembly Cells

    7.5.2 Automatic Flexible-Assembly Cells

    7.6 Assembly Lines with Flexible-Assembly Cells, Interconnected by Manual Work Points

    7.6.1 Solution Examples

    7.6.2 Summary

    8. Stored Program Controllers [46]

    8.1 Introduction

    8.2 Design of Stored Program Controllers

    8.2.1 Input Modules

    8.2.2 Signal Processing Modules

    8.2.3 Output Modules

    8.2.4 Network Modules

    8.2.5 Program

    8.3 Programming Equipment

    8.4 Modules

    8.5 Operating System

    8.6 Programming of SPCs

    8.7 Ease of Maintenance

    8.8 Availability

    8.9 Data Exchange

    9. Practical Examples

    9.1 Assembly Machines

    9.1.1 Example 1: Rocker

    9.1.2 Example 2: Valve Plate

    9.1.3 Example 3: Spray Nozzle-Spray Head

    9.1.4 Example 4: Terminal Block

    9.1.5 Example 5: High-Pressure Nozzle

    9.1.6 Example 6: Audio Cassettes

    9.1.7 Example 7: Car Fan Motor

    9.2 Flexible-Assembly Systems

    9.2.1 Example 1: Switch Block

    9.2.2 Example 2: Assembly of Clips on Car Headlights

    9.2.3 Example 3: Domestic Appliance Drive

    9.2.4 Example 4: Equipping of Printed Circuit Boards

    9.2.5 Example 5: Auxiliary Contact Block

    10. The Integration of Parts Manufacturing Processes into Assembly Equipment of Assembly Operations into Parts Production Equipment

    10.1 Introduction

    10.2 Integrated Parts Production

    10.3 The Production Machining of Parts in Assembly Equipment

    10.4 Practical Example: Assembly System with Integrated Parts Production

    10.5 The Integration of Assembly Processes into Parts Production Processes

    10.6 The Integration of Parts Production into Assembly Equipment within the Concept of Just-in-Time Production

    10.7 Limits for the Integration of Production Processes

    11. Planning and Efficiency of Automated Assembly Systems

    11.1 Introduction

    11.2 Requirement List

    11.3 Product Analysis

    11.4 Assembly Sequence Analysis

    11.4.1 Product Design and Assembly Situation

    11.4.2 Assembly Sequence

    11.5 Workpiece Carrier Design

    11.5.1 Introduction

    11.5.2 Design Examples of Workpiece Carriers

    11.6 Function Analysis

    11.7 Determination of Cycle Time

    11.8 Layout Planning

    11.8.1 Principles of Layout Planning

    11.8.2 Layout Examples

    11.9 Determination of Personnel Requirement

    11.10 Determination of Availability

    11.10.1 Parts Quality

    11.10.2 Number of Stations

    11.10.3 Availability of Individual Stations

    11.10.4 System Structure

    11.10.5 Initial Operation Characteristics

    11.10.6 Personnel Qualifications

    11.11 Assembly Systems

    11.11.1 Cycle Time

    11.11.2 System Structure - Integration of Necessary Manual Operations

    11.11.3 Conditions on the Periphery of Automatic Assembly

    11.11.4 Summary

    11.12 Investment Calculations

    11.13 Evaluation And Selection

    11.13.1 Machine Hourly Rate

    11.13.2 Personnel-Related Costs

    11.13.3 Work-Point Cost Calculation

    11.14 Optimized Overall Solution

    11.15 Computer-Aided Planning of Automated Assembly Systems

    11.15.1 CAD Layout Planning

    11.15.2 Simulation Technique

    12. Practical Example: Planning and Realization of an Automated Assembly System

    12.1 Introduction

    12.2 Planning Procedure

    12.2.1 Requirement List

    12.2.2 Product Analysis

    12.2.3 Assembly Sequence Analysis

    12.2.4 Function Analysis

    12.2.5 Determination of Cycle Time

    12.2.6 Layout Planning

    12.2.7 Determination of Personnel Requirement

    12.2.8 Determination of Availability

    12.3 Detailed Planning of Assembly System

    12.3.1 Introduction

    12.3.2 Machine I

    12.3.3 Machine II

    12.3.4 Machine III

    12.3.5 Machine IV

    12.3.6 Machine V

    12.3.7 Machine VI

    12.3.8 Machine VII

    12.3.9 Machine VIII

    12.3.10 Machine IX

    12.4 Investment Calculations

    12.5 Evaluation and Selection/Work Point Cost Comparison

    12.6 Investment Risks

    13. The Operation of Automated Assembly Systems

    13.1 Prerequisites for Initial Running

    13.1.1 Parts Quality

    13.1.2 Functional Reliability of the System

    13.1.3 Practical Example of Fault Time Determination by MANALYS on an Automatic Assembly System

    13.2 Payment

    13.3 Maintenance

    13.4 Work Safety

    14. Outlook

    15. References

    16. Index

Product details

  • No. of pages: 414
  • Language: English
  • Copyright: © Butterworth-Heinemann 1989
  • Published: September 20, 1989
  • Imprint: Butterworth-Heinemann
  • eBook ISBN: 9781483163383

About the Author

Bruno Lotter

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