Ergonomics interventions to reduce musculoskeletal risk factors in a truck manufacturing plant

Ergonomic interventions may potentially reduce MSDs, but the context of industries (barriers, ever-changing situations, dialogue processes) might play a significant role in the success of interventions. This study evaluates the effectiveness of ergonomic interventions including engineering/technical and organizational interventions, and the involvement of the stakeholders in reducing musculoskeletal risk factors/symptoms. A pre-post-test experimental study in non-randomized groups was performed over three years in a sector of a truck assembly plant. The mean age of the operators in the sector for the initial and second assessment time was 42.0 (±7.6) years and 39.0 (±8.7), respectively. The mean length of work experience in the current job was 15.2 (±7.2) years and 13.9 (±7.3) for the initial and second assessment times, respectively. Five engineering ergonomic solutions and organizational interventions were implemented after a comprehensive ergonomic analysis. The organizational interventions consisted mostly of transferring and redistributing the tasks, i.e., ergonomically balancing and redesigning of the workstations. Before performing the interventions, the findings of the ergonomic study were presented at several meetings to encourage the involvement of the stakeholders (including managers, engineers, and operators) in the interventions. This study showed that a combination of ergonomic measures—engineering and organizational interventions—could reduce physical workloads. Musculoskeletal symptoms decreased after interventions although the difference was not significant.     

Simplified anode architecture for PEMFC systems based on alternative fuel feeding: Experimental characterization and optimization for automotive applications

The need to reduce PEMFC systems cost as well as to increase their durability is crucial for their integration in various applications and especially for transport applications. A new simplified architecture of the anode circuit called Alternating Fuel Feeding (AFF) offers to reduce the development costs. Requiring a new stack concept, it combines the simplicity of Dead-End Anode (DEA) with the operation advantages of the hydrogen recirculation. The three architectures (DEA, recirculation and AFF) are compared in terms of performance on a 5-kW test bench in automotive conditions, through a sensitivity analysis. A gain of 17% on the system efficiency is observed when switching from DEA to AFF. Moreover, similar performances are obtained both for AFF and for recirculation after an accurate optimization of the AFF tuning parameters. Based on DoE data, a gain of 25% on the weight of the anodic line has been identified compared to pulsed ejector architecture and 43% with the classic recirculation architecture with blower only (Miraï).     

Numerical simulation of typical contact situations of brake friction materials

In the paper, a model typical for contact situations of automotive brakes is established based on the method of movable cellular automata. The processes taking place at local contacts in an automotive brake system are analysed. Based on microscopic and micro-analytical observations, the following contact situations were simulated: (i) a couple of ferritic steel against pearlitic steel, both covered by an oxide layer mixed with graphite nanoparticles and (ii) the same situation but without oxide layers. The results of calculated mean coefficients of friction of the oxide-on-oxide contact correspond well to expected values for a real braking system, whereas steel-on-steel contact are twice as high. This allows one to make some conclusions; for example, oxide formation will take place more quickly than friction layer elimination, and finally this is responsible for the stabilisation of the coefficient of friction.     

Failure of a Cast Aluminum Engine Head in a High Performance Application

The investigation described in this article examined a cast aluminum head used in a high performance (drag racing) application. These engine heads had been failing within a few seconds of startup. A sample head was examined to determine the cause. Visual inspection found two cracks on the exhaust side of the head. One crack initiated at the bottom of a spark plug well. The head was then sectioned for metallographic examination and fracture analysis. Metallographic examination revealed a large number of shrinkage pores throughout the casting. The fracture surface intersected many of these shrinkage pores. A significantly sized pore was located near the bottom of the suspect spark plug well near a stress-concentrating feature. This pore acted as the crack-initiating defect, which caused the engine head to fail.     

Design and evaluation of an active electromechanical wheel suspension system

This paper presents an electromechanical wheel suspension, where the upper arm of the suspension has been provided with an electric levelling and a damper actuator, both are allowed to work in a fully active mode. A control structure for the proposed suspension is described. The complex design task involving the control of the electric damper and its machine parameters is tackled by genetic optimisation. During this process, these parameters are optimised to keep the power dissipation of the electric damper as low as possible, while maintaining acceptable comfort and road-holding capabilities. The results of the evaluations carried out demonstrate that the proposed suspension can easily adopt its control parameters to obtain a better compromise of performance than that offered by passive suspensions. If the vehicle is to maintain acceptable performance during severe driving conditions, the damper has to be unrealistically large. However, if the electric damper is combined with a hydraulic damper, the size of the electric damper is significantly reduced. In addition, the design of the electric damper with the suggested control structure, including how it regenerates energy, is discussed.     

Heat-integrated reactor concepts for catalytic reforming and automotive exhaust purification

Optimal solutions in environmental catalysis require a well-coordinated development of catalysts and of process design. This contribution is devoted to energy integrated design concepts for fuel reforming and for automotive exhaust purification. The examples presented demonstrate the importance of an innovative process design for optimal utilization of existing catalysts and show the potential of future developments.

New concepts for steam reforming through the efficient coupling of the endothermic reforming reaction with an exothermic combustion reaction are discussed in the first part. These concepts have been implemented for methanol steam reforming in a counter-current reactor with distributed side feed of burner gas and for methane steam reforming in a modular reactor with a co-current reaction section for the endothermic and the combustion reaction and attached counter-current heat exchangers. Both applications employ the so-called folded sheet reactor design, which ensures an excellent heat transfer between the reforming and combustion channels and efficient heat recovery.

A similar design solution is introduced for the apparently different case of automotive exhaust purification. The proposed concept aims at decoupling exhaust after-treatment from engine control. Its main component is a counter-current heat exchanger with integrated purification stages for HC-oxidation, NO_X storage and reduction and soot filtering. A small catalytic burner at the hot end of the heat exchanger provides both heat and oxidizing or reducing agents on demand. A new soot filter design allows for safe soot filter regeneration.     

Is implementation of continuous improvement possible? An evolutionary model of enablers and inhibitors

The purpose of this article is to present an evolutionary model of the enablers and inhibitors affecting the implementation and sustainability of continuous improvement. With this aim, a qualitative study using the grounded theory was carried out. Interviews were conducted with managers responsible for continuous improvement in first‐tier suppliers in the automotive sector. As a result, two existing lines of research in the continuous improvement literature are synthesized: on one hand, the literature concerning the enablers and barriers associated with continuous improvement sustainability; and on the other, the literature concerning the evolutionary model. © 2011 Wiley Periodicals, Inc.     

基于ATmega128单片机的汽车太阳能充电控制器

利用车上太阳能电池驱动换风扇并作为汽车电瓶辅助充电电源。由ATmega128为核心构成太阳能电池驱动换风扇和电瓶充电的控制系统。这个控制器测量车内外温度、太阳能电池电压、汽车电瓶电压,根据车内外温差自动控制换气风扇工作,根据太阳能电池输出状态和电瓶状态控制充电过程。最后,基于给出的软硬件设计构建了实验系统,进行了实验和总结。     

汽车覆盖件冲压工艺/模具计算机辅助技术的发展现状

系统全面地论述了汽车覆盖件冲压模具数字化技术CAD／CAM／CAPP的发展现状，总结了目前存在的问题，并指出了未来的研究发展方向。