Assembly Automation and Product Design, Second Edition

The design for assembly (DFA) method has become a widely used way for companies to introduce competitive designs at reduced costs. This text places the consideration and application of automatic assembly in the context of DFA, addressing product design for both automated and manual assembly processes. The author enumerates the components, processes, performance, and comparative economics of several types of automatic assembly systems. To this end, the book includes specific information on equipment such as transfer devices, parts feeders, feed tracks, placing mechanisms, and robots. This is an ideal reference and guide for manufacturing, product design, mechanical, and industrial engineers.

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.

INTRODUCTIONHistorical Development of the Assembly ProcessChoice of Assembly MethodSocial Effects of Automation References AUTOMATIC ASSEMBLY TRANSFER SYSTEMS Continuous Transfer Intermittent TransferIndexing MechanismsOperator-Paced Free-Transfer Machine References AUTOMATIC FEEDING AND ORIENTING - VIBRATORY FEEDERS Mechanics of Vibratory ConveyingEffect of FrequencyEffect of Track Acceleration Effect of Vibration Angle Effect of Track AngleEffect of Coefficient of FrictionEstimating the Mean Conveying VelocityLoad SensitivitySolutions to Load Sensitivity Spiral ElevatorsBalanced FeedersOrientation of Parts Typical Orienting SystemEffect of Active Orienting Devices on Feed Rate Analysis of Orienting SystemsPerformance 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 FEEDERSReciprocating-Tube Hopper Feeder Centerboard Hopper Feeder Reciprocating-Fork Hopper FeederExternal Gate Hopper FeederRotary-Disk Feeder Centrifugal Hopper FeederStationary-Hook Hopper Feeder Bladed-Wheel Hopper FeederTumbling-Barrel Hopper Feeder Rotary-Centerboard Hopper FeederMagnetic-Disk Feeder Elevating Hopper FeederMagnetic Elevating Hopper Feeder Magazines References FEED TRACKS, ESCAPEMENTS, PARTS-PLACEMENTMECHANISMS, AND ROBOTS Gravity Feed Tracks Powered Feed Tracks Escapements Parts-Placing MechanismsAssembly RobotsReferences PERFORMANCE AND ECONOMICS OF ASSEMBLY SYSTEMSIndexing Machines Free-Transfer MachinesBasis for Economic Comparisons of Automation Equipment Comparison of Indexing and Free-Transfer MachinesEconomics of Robot AssemblyReferences DESIGN FOR MANUAL ASSEMBLYIntroductionWhere Design for Assembly Fits in the Design Process General Design Guidelines for Manual Assembly Development of a Systematic DFA Analysis MethodDFA Index Classification System for Manual Handling Classification System for Manual Insertion and FasteningEffect of Part Symmetry on Handling TimeEffect of Part Thickness and Size on Handling Time Effect of Weight on Handling TimeParts Requiring Two Hands for ManipulationEffects of Combinations of Factors Threaded Fasteners Effects of Holding Down Problems with Manual Assembly Time StandardsApplication of the DFA Method Further General Design Guidelines ReferencesPRODUCT DESIGN FOR HIGH-SPEED AUTOMATIC ASSEMBLY AND ROBOT ASSEMBLY IntroductionDesign of Parts for High-Speed Feeding and Orienting Example Additional Feeding Difficulties High-Speed Automatic InsertionExample Analysis of an AssemblyGeneral Rules for Product Design for Automation Design of Parts for Feeding and OrientingSummary of Design Rules for High-Speed Automatic Assembly Product Design for Robot Assembly ReferencesPRINTED-CIRCUIT-BOARD ASSEMBLYIntroductionTerminologyAssembly Process for PCBsSMD TechnologyEstimation of PCB Assembly Costs Worksheet and Database for PCB Assembly Cost Analysis PCB Assembly - Equations and Data for Total Operation Cost Glossary of TermsReferencesFEASIBILITY STUDY FOR ASSEMBLY AUTOMATIONMachine Design Factors to Reduce Machine DowntimeDue to Defective PartsFeasibility StudyReferencesProblemsAppendix A: Simple Method for the Determination of the Coefficient of Dynamic Friction The Method Analysis Precision of the Method DiscussionReferenceAppendix B: Out-of-Phase Vibratory Conveyors Out-of-Phase Conveying Practical ApplicationsReferenceAppendix C: Laboratory Experiments Performance of a Vibratory-Bowl FeederPerformance of a Horizontal-Delivery Gravity Feed Track ConclusionsAppendix D: Feeding and Orienting Techniques for Small PartsCoding System Feeding and Orienting Techniques Orienting Devices for Vibratory-Bowl Feeders Nonvibratory Feeders NomenclatureIndex