基于人因学原理的一板成型纸包装结构设计

一板成型结构可最大限度地节省材料并简化纸板组装加工程序,生产效率较高,同时不需胶粘,绿色环保,具有较好的市场发展前景。借鉴成功的设计案例,对普通PC硬盘包装进行了纵向结构延伸和纵、横双向结构延伸的改进设计;另外,还设计了具有销售和展示双重功能的一板成型的纸包装结构。     

Position Measurement in Industrial Drives by Means of Low-Cost Resolver-to-Digital Converter

A fully integrated board for resolver-to-digital conversion is proposed in this paper. It is based on a combined analog/digital circuit, which allows one to track the shaft angle of a standard resolver in a digital form. Furthermore, the board also provides the feeding signal for the resolver-rotor circuit. All the tuning and configuration settings, which allow one to adapt different kind of resolvers to the proposed system, can be easily implemented directly on the board. The final assembly is a compact low-cost resolver-to-digital converter. The entire board design and implementation are described in this paper. In addition, several tests at different resolver speeds have been performed for validation.     

Process and production planning for circuit board assembly

Process planning output can be post-processed into criteria for job scheduling decisions in printed circuit board assembly using surface-mount technology (SMT). Artificial intelligence-based techniques used in computerized planning and scheduling systems in other industries can be extended to printed circuit board operations. These techniques include blackboard architectures, object-oriented programming systems, and nonmonotonic reasoning systems. These techniques were used to demonstrate a unique architecture of blackboard systems that communicate via object-oriented messages to arrive at a shop-floor process plan and production schedule. The methodology was specialized to the assembly of printed circuit boards using surface-mounted components in a high-variety/low-volume product mix. The assembly facility was represented as a hierarchical object of product, process, and organizational knowledge. The system of working heuristics was integrated within a prototype environment with the practitioners that assisted in its development. The end result is a good working methodology for system development, implementation, and maintenance by knowledge worker involvement.     

Optimal versus heuristic scheduling of surface mount technology lines

This paper presents and compares an exact and a heuristic approach for scheduling of printed wiring board assembly in surface mount technology (SMT) lines. A typical SMT line consists of several assembly stations in series and/or in parallel, separated by finite intermediate buffers. The objective of the scheduling problem is to determine the detailed sequencing and timing of all assembly tasks for each individual board, so as to maximize the line's productivity, which is defined in terms of makespan for a mix of board types. The limited intermediate buffers between stations result in a scheduling problem with machine blocking, where a completed board may remain on a machine and block it until a downstream machine becomes available. In addition, limited machine availability due to scheduled downtimes is considered. The exact approach is based on a mixed integer programming formulation that can be used for optimization of assembly schedules by using commercially available software for integer programming, whereas the heuristic approach is designed as a combination of tabu search and a set of dispatching rules. Numerical examples modelled after real-world SMT lines and some computational results are provided to illustrate and compare the two approaches.     

Simulation-based performance analysis and optimization of electronics assembly equipment

Due to the high degree of automation in modern printed circuit board (PCB) assembly, production planning and scheduling in this industry relies heavily on the accuracy of the underlying models of the automated machinery. In this paper, the derivation of such mathematical models is exemplified for one of the most wide-spread machine types (the so-called chip shooter). Moreover, a simulation system for practical use in the electronics assembly is presented which incorporates various types of assembly machines. It serves as a tactical production planning aid as well as a test field for the analysis of the kinematic processes of PCB assembly machines. Such simulation, tailored to the specifics of a production environment, gives reliable estimates of the achievable production volume. Considerable deviations between the performance figures provided by the machine supplier and the actual result can thus be explained, and potential assembly system configurations be compared by drawing on reliable measures. Since the equipment is modelled at a level which takes precise account of its specific kinematics, a detailed analysis of the operations of the individual machine can also be performed revealing potential bottlenecks in its design. These insights are used to optimize machine design and control. Methods based on graph theory as well as on modern numerical search algorithms have been developed for the latter purpose. They lead to considerable performance improvements.     

基于Ansys的双A型瓦楞纸板稳定性分析

目的基于Ansys研究大中型运输包装堆码过程中纸质外围框的双A型瓦楞纸板失稳问题。方法使用Ansys软件并结合APDL语言构建双A型瓦楞纸板有限元模型,然后对该模型进行特征值屈曲分析,得到使纸板发生屈曲的最小临界载荷和屈曲后纸板的变形情况,最后改变纸板的高度与长度,再进行多次特征值屈曲分析,分析纸板的高度和长度与纸板临界屈曲载荷的关系。结果纸板的临界屈曲载荷与纸板的长度成正比,与纸板高度的平方成反比。结论纸质外围框双A型瓦楞纸板更加适合包装高度较低的产品,以减少失稳的可能性,当双A瓦楞纸板所承受的力大于临界屈曲载荷时,可以在瓦楞纸板的外表面添加胶合板加强筋,承担一部分的承载压力,从而使瓦楞受力在临界屈曲载荷之下。     

A comparison of inventory cost reduction strategies in a JIT manufacturing system

Although many companies have found JIT manufacturing to be a very effective manufacturing strategy, few models have been developed which can help direct JIT efforts. This article discusses some of the problems with modelling JIT manufacturing, it describes some simple models of inventory costs in a JIT system and it uses these models to evaluate alternative inventory-cost reduction strategies in a printed circuit board (PCB) assembly system.     

An examination of routeing flexibility for small batch assembly of printed circuit boards

In this paper, we examine and quantify the effects of introducing new processing flexibility in the rapidly changing environment of printed circuit board (PCB) assembly. Specifically, we perform experiments designed to establish the benefits and determine the limitations associated with the introduction of routeing flexibility. We examine system behaviour as batch sizes are reduced in an environment characterized by moderate set-up requirements. We further demonstrate that the performance of flexible routeing policies in this environment is adversely affected by larger batch sizes and that the introduction of routeing flexibility leads to improved system performance in small batch assembly.     

A Petri Net based approach to determine the disassembly strategy of a product

In order to protect the environment and regain value added to products, a process known as disassembly has come into the limelight. This process is to be applied to reuse abandoned goods and materials. Manufacturers are being forced to establish disassembly plants and to develop their products' designs so as to maintain the government's dictate to dispose off their products in an environmentally responsible manner. This research presents a cost-based heuristic analysis for a circuit board assembly. Various components of the product and their assembly relationships are represented by a Petri Net diagram. Firing the transitions of the disassembly Petri Net is integrated with cost-based indices to develop an effective disassembly strategy. The methodology discussed here simplifies the decisionmaking process involved in disassembly planning. A comprehensive disassembly process planning system is proposed here and is exemplified by a case study of circuit board assembly.     

Workload planning in small lot printed circuit board assembly

The problem of workload planning in small lot printed circuit board (PCB) assembly concerns the determination of the daily mix of production orders to be released into the production system. When switching from one production order (board type) to another, a considerable set-up time is incurred based on the number of component feeders to be replaced in the component magazine of the assembly machines. To support the order-mix decision faced by a major electronics manufacturer, two versions of a linear programming model are developed. The models differ primarily in their degree of aggregation and their computational effort. In order to reduce the aggregational error incurred, a fuzzy approach is developed to estimate the number of component set-ups at automatic SMD placement machines. Our numerical investigation reveals that sufficiently accurate solutions may be obtained from a highly aggregate fuzzy LP-model and this is achieved with considerably less computational effort than with a more detailed LP-model. We also demonstrate the potential suitability of the fuzzy LP-model for implementation within an interactive decision support system.     

A simultaneous-mounting process for automated printed circuit board assembly

Current robotized printed circuit board assembly systems allow one component to be inserted onto the board at a time and the corresponding design usually causes complicated operation planning problems for plant engineers. This paper addresses an opportunity for productivity improvement in automated printed circuit board assembly through the design of a new assembly mechanism from plant engineer's viewpoint. The mechanism not only will allow simultaneous insertions of multiple components but also will simplify the component placement planning task.     

Sequencing procedure for balancing the workloads variations in case of mixed model assembly system with multiple secondary feeder lines

In order to increase flexibility and reduce costs, assembly systems are changing from simple mixed-model assembly lines, to multi-lines systems, where some components are assembled in secondary lines, called feeder lines, connected to the main line by a ‘pull philosophy’. The production of different models in such a complex multi-lines assembly system, where the tasks to perform could be very different from model to model, impacts the production with very high workload time variations, with the consequence of lack of productivity. If operators can perform tasks on different stations on both the feeder and the main lines these time variations can generally be absorbed. But if working across the stations is not possible (closed stations), the balancing of these workload time variations becomes critical. In such contexts the consolidated approach, that allows to configure mixed-model-multi lines assembly system with a single average model representative of the whole mix, can be very limited and is unable to bring substantial results. This paper aims to introduce an innovative sequencing model for mixed-model-multi-lines system, in the case of closed stations, in which it is possible to obtain, after a first long term configuration, a short term balancing, using an appropriate sequencing, for a given production mix and characteristics of the assembly system. The proposed procedure is applied to un-paced assembly lines and validated through simulation and industrial applications.     

Scheduling manufacturing systems for delayed product differentiation in agile manufacturing

Production of customized products to respond to changing markets in a short time and at a low cost for agile manufacturing can be implemented with delayed product differentiation in a manufacturing system. The successful implementation of delayed product differentiation lies in efficient scheduling of the manufacturing system. Scheduling problems in implementing delayed product differentiation in a general flexible manufacturing system are defined, formulated and solved here. The manufacturing system consists of two stages: machining and assembly. At the machining stage, a single machine is used to produce standard component parts for assembly products. These parts are then assembled at the assembly stage by multiple identical assembly stations to form customized products. The products to be produced in the system are characterized by their assembly sequences represented by digraphs. The scheduling problem is to determine the sequence of products to be produced in the system so that the maximum completion time (makespan) is minimized for any given number of assembly stations at the assembly stage. Based on the representation of assembly sequence of the products, three production modes are defined: production of a single product with a simple assembly sequence ; production of a single product with a complex assembly sequence ; and production of N products . According to the three defined production modes, the associated scheduling problems are defined as G s scheduling problems, G c scheduling problems and N-product scheduling problems, respectively. Optimal and heuristic methods for solving the scheduling problems are developed. The computational experiment shows that the heuristics provide good solutions to the scheduling problems.     

Rolling balance board of adjustable geometry as a tool to assess balancing skill and to estimate reaction time delay

The relation between balancing performance and reaction time is investigated for human subjects balancing on rolling balance board of adjustable physical parameters: adjustable rolling radius R and adjustable board elevation h. A well-defined measure of balancing performance is whether a subject can or cannot balance on balance board with a given geometry (R, h). The balancing ability is linked to the stabilizability of the underlying two-degree-of-freedom mechanical model subject to a delayed proportional–derivative feedback control. Although different sensory perceptions involve different reaction times at different hierarchical feedback loops, their effect is modelled as a single lumped reaction time delay. Stabilizability is investigated in terms of the time delay in the mechanical model: if the delay is larger than a critical value (critical delay), then no stabilizing feedback control exists. Series of balancing trials by 15 human subjects show that it is more difficult to balance on balance board configuration associated with smaller critical delay, than on balance boards associated with larger critical delay. Experiments verify the feature of the mechanical model that a change in the rolling radius R results in larger change in the difficulty of the task than the same change in the board elevation h does. The rolling balance board characterized by the two well-defined parameters R and h can therefore be a useful device to assess human balancing skill and to estimate the corresponding lumped reaction time delay.     

Detection of capacitor electrolyte residues with FTIR in failure analysis

Detecting leakage from liquid aluminum electrolytic capacitors is not easy. Typically there is very little evidence of leakage because the electrolyte is volatile and leaves behind only trace residues. Liquid aluminum electrolytic capacitors are known to cause catastrophic failures where there is complete loss of functionality due to a short or open circuit. In the study presented in this paper, printed circuit board assemblies from a test and measurement system used in a clean room environment failed. Two units failed, causing burning in a particular area on the printed circuit board assembly. The failure area included several surface mount liquid aluminum electrolytic capacitors, and several others were mounted very close to the burnt region. A study was initiated to evaluate the cause of failure. Careful optical inspection revealed some residues on the outer side of the rubber seals of two of the electrolytic capacitors. Through using Fourier transform infrared analysis and a process of experimentation and analysis, it was determined that the residues were produced by liquid electrolyte that leaked out of the capacitor at some point in the field. The leaked electrolyte that came out of the capacitor was believed to be the cause of failure that led to the burning of the printed circuit board assembly.     

ASSEMBLY CAPACITY MIX PLANNING WITH PRODUCT-FLEXIBLE TECHNOLOGY AND FIXTURES

Product changeover is becoming increasingly critical in planning assembly capacity which may be manual or automated with supporting part-holding and conveying devices. The basic choice is between assembly systems that are more product-specific, such as dedicated assembly heads, and those that are relatively flexible, such as manual or robotic systems. A rigid system would require frequent transitions as product variety increases, and may nullify any scale economies. A flexible system, on the other hand, though more expensive, can incorporate product changeovers more easily and would therefore require less transitions, creating scope economies. A quantitative analysts to study such interactions of system parameters with a view to developing understanding and procedures for dynamic planning of flexible assembly capacity is the objective of this paper.     

Improvement of lubrication and cooling in grinding

The presence of air boundary layer around a grinding wheel impedes the proper entry of cutting fluid into grinding zone and thereby lubrication and cooling are hampered. It leads to the thermal damage to the workpiece and rapid wheel wear. This experimental work is aimed at increasing the lubrication and cooling effects in grinding by a novel method of using scraper board. The experiments are conducted, using the scraper board, to find the critical region where the air pressure is zero. The coolant jet has then impinged into the grinding zone which is maintained within the critical region. The requirement of specific energy, surface texture, and mechanical properties of the ground surface are analyzed and compared with the traditional grinding and the grinding at various positions of scraper board. Results show that the grinding ratio improved by 35.6and 119%, surface roughness decreased by 36 and 54.2%, while the requirement of specific energy is reduced by 50.8 and 57.3% when scraper board is positioned at the critical distance in comparison to the 57.5° position and no scraper board, respectively. The results indicate that the introduction of fluid in the present method can improve the process efficiency and the product quality effectively.     

A LISP-based heuristic scheduler for automatic insertion in electronics assembly

Computer solutions have not made a very significant impact on scheduling problems. This reflects the fact that algorithmic solutions are often not appropriate for scheduling problems. Scheduling problems are more amenable to heuristic solution techniques. This paper describes a heuristic system for job scheduling in printed circuit board assembly. The main part of the system is written in Common LISP.     

Mechanism to minimise the assembly time with feeder assignment for a multi-headed gantry and high-speed SMT machine

This paper proposes the development of a mechanism to minimise the assembly time for a multi-headed gantry and high-speed surface mounting technology machine by determining the component assignment to feeder slots. Since a gantry moves long distances in order to pick components, place them on the board and then return them to the feeder slots, we classified the overall assembly time according to the different movements of a gantry. The overall assembly time is then minimised by presenting a new heuristic for the feeder assignment, consisting of Nearest Component Allocation (NCA) and Globally Updated Assignment (GUA). NCA contains information about how each component type locates closely to others on the board. Using the solution from NCA, the component distance function calculates the most representative distance between component types. Then, GUA is applied to improve the NCA solution. The experiments consist of several printed circuit boards with numbers of component types and points to be placed. Highlights of this paper are that: a classification of the gantry movements is proposed based on the average speed; a heuristic NCA-GUA for feeder assignment is developed by considering the placements on the board; the computational time is greatly reduced by NCA-GUA without degrading the solution quality; and a decision process for nozzle assignment is proposed to minimise the overall assembly time. The results show how NCA and GUA affect the final results, and how this mechanism leads to better performance than a genetic algorithms or 2-opt swap search. This comparison proves that our method provides competitive and effective solutions in terms of minimising the overall assembly time.