Assembly Automation and Product Design: 2nd Edition (Hardback) book cover

Assembly Automation and Product Design

2nd Edition

By Geoffrey Boothroyd

CRC Press

536 pages | 471 B/W Illus.

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pub: 2005-06-22
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Description

Addressing design for automated and manual assembly processes, Assembly Automation and Product Design, Second Edition examines assembly automation in parallel with product design. The author enumerates the components, processes, performance, and comparative economics of several types of automatic assembly systems. He provides information on equipment such as transfer devices, parts feeders, feed tracks, placing mechanisms, and robots.

Presenting detailed discussions of product design for assembly, the book contains over 500 drawings, tables, and equations, and numerous problems and laboratory experiments that help clarify and reinforce essential concepts. Highlighting the importance of well-designed products, the book covers design for manual assembly, high-speed automatic and robot assembly, and electronics assembly. The new edition includes the popular Handbook of Feeding and Orienting Techniques for Small Parts, published at the University of Massachusetts, as an appendix. This provides more than 100 pages packed with useful data and information that will help you avoid the costly errors that often plague high-volume manufacturing companies.

In today's extremely competitive, highly unpredictable world, your organization needs to constantly find new ways to deliver value. Performing the same old processes in the same old ways is no longer a viable option. Taking an analytical yet practical approach to assembly automation, this completely revised second edition gives you the skill set you need not only to deliver that value, but to deliver it economically and on time.

Table of Contents

INTRODUCTION

Historical Development of the Assembly Process

Choice of Assembly Method

Social Effects of Automation

References

AUTOMATIC ASSEMBLY TRANSFER SYSTEMS

Continuous Transfer

Intermittent Transfer

Indexing Mechanisms

Operator-Paced Free-Transfer Machine

References

AUTOMATIC FEEDING AND ORIENTING - VIBRATORY FEEDERS

Mechanics of Vibratory Conveying

Effect of Frequency

Effect of Track Acceleration

Effect of Vibration Angle

Effect of Track Angle

Effect of Coefficient of Friction

Estimating the Mean Conveying Velocity

Load Sensitivity

Solutions to Load Sensitivity

Spiral Elevators

Balanced Feeders

Orientation of Parts

Typical Orienting System

Effect of Active Orienting Devices on Feed Rate

Analysis of Orienting Systems

Performance of an Orienting Device

Natural Resting Aspects of Parts for Automatic Handling

Analysis of a Typical Orienting System

Out-of-Bowl Tooling

References

AUTOMATIC FEEDING AND ORIENTING - MECHANICAL FEEDERS

Reciprocating-Tube Hopper Feeder

Centerboard Hopper Feeder

Reciprocating-Fork Hopper Feeder

External Gate Hopper Feeder

Rotary-Disk Feeder

Centrifugal Hopper Feeder

Stationary-Hook Hopper Feeder

Bladed-Wheel Hopper Feeder

Tumbling-Barrel Hopper Feeder

Rotary-Centerboard Hopper Feeder

Magnetic-Disk Feeder

Elevating Hopper Feeder

Magnetic Elevating Hopper Feeder

Magazines

References

FEED TRACKS, ESCAPEMENTS, PARTS-PLACEMENT

MECHANISMS, AND ROBOTS

Gravity Feed Tracks

Powered Feed Tracks

Escapements

Parts-Placing Mechanisms

Assembly Robots

References

PERFORMANCE AND ECONOMICS OF ASSEMBLY SYSTEMS

Indexing Machines

Free-Transfer Machines

Basis for Economic Comparisons of Automation Equipment

Comparison of Indexing and Free-Transfer Machines

Economics of Robot Assembly

References

DESIGN FOR MANUAL ASSEMBLY

Introduction

Where Design for Assembly Fits in the Design Process

General Design Guidelines for Manual Assembly

Development of a Systematic DFA Analysis Method

DFA Index

Classification System for Manual Handling

Classification System for Manual Insertion and Fastening

Effect of Part Symmetry on Handling Time

Effect of Part Thickness and Size on Handling Time

Effect of Weight on Handling Time

Parts Requiring Two Hands for Manipulation

Effects of Combinations of Factors

Threaded Fasteners

Effects of Holding Down

Problems with Manual Assembly Time Standards

Application of the DFA Method

Further General Design Guidelines

References

PRODUCT DESIGN FOR HIGH-SPEED AUTOMATIC ASSEMBLY AND ROBOT ASSEMBLY

Introduction

Design of Parts for High-Speed Feeding and Orienting

Example

Additional Feeding Difficulties

High-Speed Automatic Insertion

Example

Analysis of an Assembly

General Rules for Product Design for Automation

Design of Parts for Feeding and Orienting

Summary of Design Rules for High-Speed Automatic Assembly

Product Design for Robot Assembly

References

PRINTED-CIRCUIT-BOARD ASSEMBLY

Introduction

Terminology

Assembly Process for PCBs

SMD Technology

Estimation of PCB Assembly Costs

Worksheet and Database for PCB Assembly Cost Analysis

PCB Assembly - Equations and Data for Total Operation Cost

Glossary of Terms

References

FEASIBILITY STUDY FOR ASSEMBLY AUTOMATION

Machine Design Factors to Reduce Machine Downtime

Due to Defective Parts

Feasibility Study

References

Problems

Appendix A: Simple Method for the Determination of the Coefficient of Dynamic Friction

The Method

Analysis

Precision of the Method

Discussion

Reference

Appendix B: Out-of-Phase Vibratory Conveyors

Out-of-Phase Conveying

Practical Applications

Reference

Appendix C: Laboratory Experiments

Performance of a Vibratory-Bowl Feeder

Performance of a Horizontal-Delivery Gravity Feed Track

Conclusions

Appendix D: Feeding and Orienting Techniques for Small Parts

Coding System

Feeding and Orienting Techniques

Orienting Devices for Vibratory-Bowl Feeders

Nonvibratory Feeders

Nomenclature

Index

About the Series

Manufacturing Engineering and Materials Processing

Learn more…

Subject Categories

BISAC Subject Codes/Headings:
SCI041000
SCIENCE / Mechanics / General
TEC009060
TECHNOLOGY & ENGINEERING / Industrial Engineering
TEC009070
TECHNOLOGY & ENGINEERING / Mechanical