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.
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
Biography
Geoffrey Boothroyd
