Fixture modelling for an automotive assembly line

This paper proposes an efficient fixture modelling procedure for automotive body assembly lines. A fixture model consists of two sub-models; a geometric model and a kinetic model that should be remodelled frequently whenever design changes occur. We develop an algorithm extracting the kinetic model from the geometric model of a fixture to reduce the fixture modelling time and effort. Although the geometric models of fixtures used in automotive assembly lines vary, most follow the same kinetic mechanism, the so-called slider-crank mechanism; this is a four-axis system of three revolute and one prismatic joint. The prismatic axis of a fixture represents a pneumatic actuator involving a piston and a cylinder. It is very important to identify the prismatic axis from a given geometric model to extract the kinetic model of a fixture. We use the concept of the ‘moment of inertia’, which is a measure of an object's resistance to changes in its rotation rate, to identify the prismatic axis. Since the exact computation of the moment of inertia for an arbitrary solid model requires complicated computations, we introduce an approximating method for the moment of inertia. The proposed procedure has been implemented and tested with various examples.     

Optimizing the yard layout in container terminals

The main activities of container terminals are to load outbound containers on to vessels, discharge inbound containers from vessels, and store those containers in the yard before loading (or after discharging) them. This study proposes a method for determining an optimal layout of container yards taking into consideration the storage space requirements and throughput capacities of yard cranes and transporters. Two types of yard layout are under consideration: a layout where blocks are laid out parallel to the quay and transfer points are located beside a bay per block, and a layout whose blocks are laid out perpendicular to the quay and transfer points are located at both ends of each block. Various cost factors are used for optimizing the yard layout, which include the construction cost of the ground space, the fixed overhead cost of yard cranes, and the operating costs of yard cranes and transporters. Sensitivity analysis is performed to investigate the effect of various design parameters on the optimal layout of the yard. The two types of yard layout are compared with each other, and the results of this study are compared against those for real-world yard layouts from the perspective of throughput capacity and storage space capacity.     

Development of an efficient algorithm for global optimization by simplex elimination

An efficient multi-start algorithm for global optimization is developed by introducing multi-dimensional simplexes as new expression units of attraction regions. The region elimination method generally consists of making a set of eliminated regions called attraction regions, checking adjacency between the current design point and the attraction region, and quitting local optimization for the attracted design points. The efficiency of the elimination method is considerably enhanced by supplementing general simplexes and their neighborhoods to conventional units of attraction regions of points and lines. To show the effectiveness of the proposed algorithm, mathematical problems from the literature are solved and the results are compared with several well-known multi-start algorithms. The present algorithm produces the global optimum in all problems more efficiently than the variants of the multi-start method. Several types of truss, frame, and composite material structures are optimized as engineering applications. Many local optima are found and the differences among the local optima are not negligibly small. These results suggest that an efficient and reliable global optimizer is strongly required in some fields of engineering optimization.     

Origin of Capacity Fading in Nano-Sized Co3O4 Electrodes: Electrochemical Impedance Spectroscopy Study

Transition metal oxides have been suggested as innovative, high-energy electrode materials for lithium-ion batteries because their electrochemical conversion reactions can transfer two to six electrons. However, nano-sized transition metal oxides, especially Co₃O₄, exhibit drastic capacity decay during discharge/charge cycling, which hinders their practical use in lithium-ion batteries. Herein, we prepared nano-sized Co₃O₄ with high crystallinity using a simple citrate-gel method and used electrochemical impedance spectroscopy method to examine the origin for the drastic capacity fading observed in the nano-sized Co₃O₄ anode system. During cycling, AC impedance responses were collected at the first discharged state and at every subsequent tenth discharged state until the 100th cycle. By examining the separable relaxation time of each electrochemical reaction and the goodness-of-fit results, a direct relation between the charge transfer process and cycling performance was clearly observed.     

Dimethylsilylbis(1‐indenyl) zirconium dichloride/methylaluminoxane catalyst supported on nanosized silica for propylene polymerization

A dimethylsilylene‐bridged metallocene complex, (CH₃)₂Si(Ind)₂ZrCl₂, was supported on a nanosized silica particle, whose surface area was mostly external. The resulting catalyst was used to catalyze the polymerization of propylene to polypropylene. Under identical reaction conditions, a nanosized catalyst exhibited much better polymerization activity than a microsized catalyst. At the optimum polymerization temperature of 55°C, the former had 80% higher activity than the latter. In addition, the nanosized catalyst produced a polymer with a greater molecular weight, a narrower molecular weight distribution, and a higher melting point in comparison with the microsized catalyst. The nanosized catalyst's superiority was ascribed to the higher monomer concentration at its external active sites (which were free from internal diffusion resistance) and was also attributed to its much larger surface area. Electron microscopy results showed that the nanosized catalyst produced polymer particles of similar sizes and shapes, indicating that each nanosized catalyst particle had uniform polymerization activity. © 2007 Wiley Periodicals, Inc. J Appl Polym Sci, 2008     

Precise preparation of four-arm-poly(ethylene glycol)-block-poly(trimethylene carbonate) star block copolymers via activated monomer mechanism and examination of their solution properties

The polymerization of trimethylene carbonate (TMC) in the presence of HCl·Et₂O via activated monomer mechanism was performed to synthesize 4a-PEG-b-PTMC star block copolymers composed of poly(ethylene glycol) (PEG) and poly(trimethylene carbonate) (PTMC) using four-arm (4a) PEG as an initiator. The TMC conversion and molecular weight of PTMC increased linearly with the polymerization time or the feed ratios of the TMC to 4a-PEG in the presence of HCl·Et₂O in CH₂Cl₂ at 25 °C. The obtained PTMC had molecular weights close to the theoretical value calculated from TMC to PEG molar ratio and exhibited monomodal GPC curve. We prepared successfully 4a-PEG-b-PTMC star block copolymers without metal catalyst at room temperature via living ring-opening polymerization (ROP) of TMC from 4a-PEG as an initiator in the presence of HCl·Et₂O as a monomer activator. The CMCs of the 4a-PEG-b-PTMC star block copolymers determined from fluorescence measurements. The CMCs of the 4a-PEG-b-PTMC star block copolymers decreased in the order of the increase in the PTMC segment. The partition equilibrium constant, K_v, which is an indicator of the hydrophobicity of the micelles of the 4a-PEG-b-PTMC star block copolymers in aqueous media, increased with the increase in the PTMC segment. In conclusion, we confirmed that the 4a-PEG-b-PTMC star block copolymers form micelles and hence may be potential hydrophobic-drug delivery vehicles.     

Simultaneous pulsed current activated combustion synthesis and densification of NbSi2–SiC composite

Dense ultrafine NbSi₂–SiC composite was synthesized by the pulsed current activated combustion synthesis (PCACS) method within 3 min in one step from mechanically activated powders of NbC and 3Si. Simultaneous combustion synthesis and densification were accomplished under the combined effects of a pulsed current and mechanical pressure. Highly dense NbSi₂–SiC composite with relative density of up to 97% was produced under simultaneous application of a 60 MPa pressure and the electric current. The average grain size and mechanical properties (hardness and fracture toughness) of the composite were investigated.     

Silicon oxidation by aerial diffusion of active oxygen species from UV-irradiated TiO<Subscript>2</Subscript>

Silicon oxidation by the aerial diffusion of active oxygen species from a UV-irradiated TiO₂ surface was evaluated and characterized. The key point was to confirm the oxidation possibility of inorganic materials such as silicon under a photocatalytic remote scheme. In this study, it was confirmed that the remote oxidation of silicon substrates would occur by the aerial diffusion of active oxygen species from UV-irradiated TiO₂ surfaces, and that the oxides have comparable properties to the thermally grown oxide. Remote oxidation using UV-irradiated TiO₂ is shown to be a viable alternative method for the fabrication of nano-scale silicon oxide.     

Application of physical vapor deposition process to modify activated carbon fibers for ozone reduction

This study utilized the activated carbon fiber (ACF) modified with metal catalyst via physical vapor deposition (PVD) process (ACF/PVD) to diminish ozone. Furthermore, the ozone removal efficiency of ACF/PVD was compared with that of original ACF and ACF modified with metal catalyst via impregnation process (ACF/impregnation). In addition to the kinds of coated metal and the inlet ozone concentrations, the effects of the coating thickness and the reaction temperature on ACF/PVD for ozone removal were also examined. The results indicate that the ozone removal efficiency of ACF/PVD is better than that of original ACF and ACF/impregnation. The ozone removal efficiency of different metal-coated ACF/PVD in the superior order is gold (Au), and manganese (Mn). The increase of Au-coated thickness (3 nm to 80 nm) on ACF/PVD will enhance the ozone removal. However, when the Mn-coated thickness on ACF/PVD is larger than 15 nm, the ozone removal efficiency displays a declining trend. Furthermore, a higher reaction temperature will result in a better ozone removal of ACF/PVD and the original ACF.     

Methane steam reforming for synthetic diesel fuel production from steam-hydrogasifier product gases

Steam-methane reforming (SMR) reaction was studied using a tubular reactor packed with NiO/γ-Al₂O₃ catalyst to obtain synthesis gases with H₂/CO ratios optimal for the production of synthetic diesel fuel from steam-hydrogasification of carbonaceous materials. Pure CH₄ and CH₄-CO₂ mixtures were used as reactants in the presence of steam. SMR runs were conducted at various operation parameters. Increasing temperature from 873 to 1,023 K decreased H₂/CO ratio from 20 to 12. H₂/CO ratio decreased from 16 to 12 with pressure decreasing from 12.8 to 1.7 bars. H₂/CO ratio also decreased from about 11 to 7 with steam/CH₄ ratio of feed decreasing from 5 to 2, the lowest limit to avoid severe coking. With pure CH₄ as the feed, H₂/CO ratio of synthesis gas could not be lowered to the optimal range of 4–5 by adjusting the operation parameters; however, the limitation in optimizing the H₂/CO ratio for synthetic diesel fuel production could be removed by introducing CO₂ to CH₄ feed to make CH₄-CO₂ mixtures. This effect can be primarily attributed to the contributions by CO₂ reforming of CH₄ as well as reverse water-gas shift reaction, which led to lower H₂/CO ratio for the synthesis gas. A simulation technique, ASPEN Plus, was applied to verify the consistency between experimental data and simulation results. The model satisfactorily simulated changes of H₂/CO ratio versus the operation parameters as well as the effect of CO₂ addition to CH₄ feed.