Browse Topic: Production

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Dependency of Gear Honing Machine Processing Accuracy on Machine Vibration and the Vibration Reduction Considering Contribution2024-32-002004/18/2025
In recent years, accurate gear processing is required for various products to improve efficient power transmission and small noise and vibration. On the other hand, the accuracy tends to be worse by high speed processing for increasing production efficiency. Therefore, we investigated relationship between gear honing machine vibration and the accuracy. The vibration acceleration of the honing machine was measured at various conditions, and the gear accuracy was measured after processing. As results, the accuracy was observed to be affected by both the original gear accuracy before honing processing and the gear secondary rotational vibration of the machine in operation. Subsequently, we applied transfer path analysis (TPA) to investigate which directional force in operation increased the vibration. As the results, the contribution from the input force at gear processing point along normal direction was the main contributor. Then, vibration transmission characteristics of the machine
Hanioka, Hiroaki, Ogawa, Yunosuke, Yoshida, Junji, Onishi, Yoichi, Kurokawa, Yasuhiro
Technical Paper
Revolutionizing Seafood Production with Adaptive RobotsTBMG-5217812/01/2024
Robotic automation technology is reshaping food manufacturing, packaging, and handling by driving significant improvements in efficiency, quality, and flexibility. By integrating advanced artificial intelligence, computer vision, and proprietary force-sensing technology, Flexiv has introduced cutting-edge automation to the food processing sector.
Magazine Article
Contract Manufacturing: Accelerating Product DevelopmentTBMG-5217212/01/2024
Design and material choices can have a long-term impact on an original equipment manufacturer’s (OEM) production costs and product quality. When an OEM works together with an experienced contract design manufacturer (CDM) from the start of a project, many negative impacts to cost and quality can be avoided.
Magazine Article
3D-Printed Reactor Core Makes Solar Fuel Production More EfficientTBMG-5219312/01/2024
In recent years, engineers at ETH Zurich have developed the technology to produce liquid fuels from sunlight and air. In 2019, they demonstrated the entire thermochemical process chain under real conditions for the first time, in the middle of Zurich, on the roof of ETH Machine Laboratory. These synthetic solar fuels are carbon neutral because they release only as much CO2 during their combustion as was drawn from the air for their production. Two ETH spin-offs, Climeworks and Synhelion, are further developing and commercializing the technologies.
Magazine Article
SAE TOMORROW TODAY: Avant-Garde EV Company to Build in the US1340106/22/2023
While you may not have heard of Polestar, its exceptional performance, unique buying experience, and commitment to sustainability enables this novel brand to "intercept" its customers. Headquartered in Sweden and built with Scandinavian minimalism in mind, Polestar offers a friction-free, primarily digital EV buying experience which includes boutique showrooms in areas with high foot traffic--a contrast to the traditional car lot. The company recently unveiled its first electric performance SUV, the Polestar 3, which is produced in United States. With a focus on supply chain traceability and sustainability labelling, Polestar assesses their vehicles' lifetime carbon footprint, covering emissions from materials production, manufacturing, and logistics, use phase, and end of life. As part of their commitment to an electrified future, Polestar also recently partnered with the SAE Foundation to spark STEM curiosity amongst students. To learn more about this burgeoning brand, we sat down
Hineman, Marcie
Podcast
A Comparative Analysis of Fault Diagnosis by vibration signals for Critical Gear Components in Electric Vehicle Motor Testing Machines Using Machine Learning Algorithms2025-01-004005/05/2023
Electric vehicles (EVs) represent the future of the automobile industry, with the drive motor being a crucial component in modern EVs. To ensure optimal performance, a motor testing machine is used to verify the essential parameters of these electrical motors. This machine regularly evaluates electric motor characteristic curves and their electromagnetic behavior under different conditions. However, it has been observed that flaws in the testing machine's helical gear arrangement frequently cause malfunctions and suboptimal performance, affecting the efficiency of the electric vehicle production line. This research project aims to improve the motor test bench apparatus by modifying critical design parameters using machine learning and vibration signal analysis methods. Vibration signals are recorded at various gear settings, and statistical features are extracted from these signals. These signals are then classified using classifiers such as Naive Bayes and Decision Trees. Machine
S PhD, Ravikumar, V, Muralidharan, Syed, Shaul
Technical Paper
Identification and Evaluation of Passthroughs That Affect the Acoustic Performance of a Dash System2025-01-012105/05/2023
This paper discusses a systematic process that was developed to evaluate the acoustic performance of a production electric vehicle dash system. The production dash panel was tested under different configurations to understand the importance of passthroughs in the acoustics of the dash system. Results show that often the performance of the passthroughs strongly affects the overall performance of the dash system and this may become the limiting factor to increase the system STL. The dash with passthroughs was then extensively tested to understand the acoustic strength of different passthroughs and to understand how these passthroughs affect the overall performance of the dash system. Subsequently a test procedure based on flat panel tests was developed so the OEM can develop target values and the suppliers can provide test results of their passthroughs that are meaningful and useful to the OEM to help build an acoustically competitive vehicle.
Saha, Pranab, Baack, Gregory, Geissler, Christian, Kaluvakota, Srikanth, Pilz, Fernando
Technical Paper
Do EVs Snore?2025-01-007405/05/2023
As EV and PHEV adoption continues to increase more people will have direct experiences with these quieter vehicles in their daily lives. Topics such as 'propulsion sound' via Active Sound Design (ASD) and bystander safety through Acoustic Vehicle Alerting Systems (AVAS) have been discussed widely for many, many years...but who is talking about Charging Noise? Charging noise is a less spoken about topic because most EV / PHEV owners will charge their vehicles at their home, in their garage or their driveway, overnight when they are sleeping. Because of that people do not think much about charging noise. But anyone who has plugged in their car overnight will tell you a strange cacophony of sounds come from the car...and some can be downright concerning. In this paper data from several production EVs were measured during their normal charging cycle. Binaural recordings made inside and outside the vehicle are analyzed using psychoacoustics metrics to see what sounds would cause the most
Marroquin, Marc, Bray, Wade
Technical Paper
Medical Device Machining: Precise and Reliable Parts for Critical ApplicationsTBMG-4695311/01/2022
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Magazine Article
SAE TOMORROW TODAY: Additive Manufacturing on Earth and Beyond1331409/23/2022
From industrial to medical to space, laser additive manufacturing and 3-D printing has the potential to transform production across nearly every sector. With almost one hundred years in business and nearly half a century in laser technology, TRUMPF has long been known as the gold-standard in advanced manufacturing solutions that now include additive manufacturing and 3-D printing. The company's advancements in production technology span space exploration, medical devices, and Smart Factory development. We sat down with Eliana Fu, Industry Manager for Aerospace & Medical at TRUMPF North America, to discuss how the company is transforming manufacturing processes for the better, both on earth and beyond. From assembling vehicles in space to manufacturing medical devices closer to the point of care to paving the way for the Smart Factory, TRUMPF is building the industrial world of tomorrow.
Hineman, Marcie
Podcast
Aerospace Digital Design and Manufacturing Services- DDMS2022-26-114805/26/2022
Digital Design, Manufacturing & Services (DDMS) is a digital approach to the way aerospace products are designed, manufactured, operated & serviced. The DDMS process focuses on digital methods & tools for end to end digital connectivity of data to meet the business process objectives like cost reduction and time to market, meeting our customers' expectations for quality, safety, functional and environmental performance. The paper covers DDMS technology where unique tools and technologies are developed to meet individual organization requirement which includes study of current available infrastructures in terms design, manufacturing, existing tools etc. Digital serves the long-term perspective, which is the next generation of planes, the new development of the new systems. Digital manufacturing is the use of an integrated, computer-based system comprised of simulation, 3D visualization, analytics and collaboration tools to create product and manufacturing process definitions
R, Suresh M.
Technical Paper
Mobility Energy Productivity Evaluation of Prediction-based Vehicle Powertrain Control Combined with Optimal Traffic Management2022-01-016103/29/2022
Transportation system efficiency can be defined in two ways: 1) reduction of travel times across all the vehicles in the system, and 2) reduction in total energy consumed by all the vehicles in the system. The levers to realize these efficiencies are treated as independent (i.e., vehicle and network domains), and have not been studied jointly to date. This research aims to integrate previously developed and published research on Predictive Optimal Energy Management Strategies (POEMS) and Intelligent Traffic Systems (ITS), to address the need for quantifying improvement in system efficiency resulting from a simultaneous vehicle and network optimization. POEMS and ITS are partially independent methods that do not require each other to function but whose individual effectiveness may be affected by the presence of the other. In order to evaluate the simultaneous optimizations holistically, the Mobility Energy Productivity (MEP) metric which measures the connectedness of a system while
Motallebiaraghi, Farhang, Yao, Kaisen, Rabinowitz, Aaron, Hoehne, christopher, garikapati, Venu, Holden, Jacob, Wood, Eric, Chen, Suren, Bradley, Thomas, Asher, Zachary
Technical Paper
Investigations of Process and Component Parameters for the Number of Particles and Size Distribution of a Supercharged DI-SI Engine2022-01-070003/29/2022
Due to the short mixture formation times in the direct injection of modern gasoline engines, there is an increase in the emission of undesirable particle emissions in gasoline engines. As a result of previous studies with a portable emission measurement system (PEMS) of raw emissions and cleaned emissions, the particle number (PN) of the sampling point after the catalyst was higher than before the catalyst at the same process parameters and engine operating points. Based on this reproducible phenomenon, several theories were proposed. The theories set up dealt on the one hand with the question of process control with regard to the formation of particles, but also fundamentally with the question of whether conventional exhaust gas aftertreatment systems (3-way catalytic converters) are suitable for influencing the number of particles. In addition, studies of the oil consumption via the blow-by system and its influence on particle emissions also played a role. To verify these theories
Dost, Tobias, Schambach, Ricardo, Getzlaff, Joern
Technical Paper
The investigation of a contact and element-based approach for Cohesive zone modelling in the simulation of Delamination propagation2022-01-029203/29/2022
The CAE industry always moves towards new ways to improve the productivity, efficiency and to reduce the solution times. Conventional method of Cohesive Zone Modelling has drawback of higher computation and modelling time. Due to this problem, sometimes Engineers need to avoid simulations and rely only on some sort of approximation of crack from previous designs. This approximation can lead to either product failure or overdesign of the product. A new approach is discussed in this paper to simulate crack initiation and propagation with Cohesive Zone Modelling. Conventional method uses Cohesive zone modelling with Hex or Penta elements by assigning material with cohesive properties, which increases computation and modelling time. The new approach models Cohesive zone as contact between two bodies, thus eliminating the need to use cohesive elements which will essentially reduce the computation time as well as modelling time. This approach uses Damage model method which allows modelling
Dhangar, Vinaykumar, Hosmath, Anjaney, Salunkhe, Prashant
Technical Paper
Instrumental Color Difference Measurement for Exterior Finishes, Textiles, and Colored TrimJ1545_20211212/30/2021
The practice applies to parts and materials used in vehicle manufacture which are intended to be acceptable color matches to a specified color standard. This practice is intended for use with parts or materials that are opaque or nearly so and does not apply to transparent materials. Materials covered by this practice include topcoat paint finishes, interior soft trim, interior and exterior hard trim, and exterior film.
Textile and Flexible Plastics Committee
Technical Paper
SAE TOMORROW TODAY: SAE: Forging a New Mobility Ecosystem - Part 11317111/12/2021
Think you know SAE? These episodes will have you thinking again. The next mobility revolution is upon us. Connected, automated and electrified transportation can provide equity of access to jobs, education, health care and beyond - but the future comes with challenges as innovators consider sustainability, resiliency and scalability of production. In part one of this special two-part series, SAE International's own Chief Growth Officer, Frank Menchaca, discusses the ways SAE is meeting the changing needs of 21st-century transportation and mobility, the organization's partnership with Argo AI and Clemson University to build the new Robotics Bootcamp, why SAE's J3016 Levels of Driving Automation was created, and the launch of SAE's Office of Sustainable Energy. Intrigued? Meet Pete. Meet Skylar. And meet Violet.
Hineman, Marcie
Podcast
An alternate CED process for low volume BIW manufacturing with single stage vertical dipping2021-28-022710/01/2021
Body in White (BIW) is a major assembly in an automobile. It is made of sheet metal components that are welded together by Resistance spot welding. Assembled BIWs are put through an anti-corrosion process called Cathodic Electrodeposition (CED) and baked to set the CED coat. CED process has an elaborate sequence of rinse cycles and coat cycles. Single stage dipping stations are used for coating large volumes of smaller components. The high-cost multi-stage setup is a commonly used process in large scale BIW manufacturing systems. In the context of small-scale batch production or prototype builds, the extensive setup is not viable. This paper studied the feasibility of CED coating large BIWs in a single stage setup. Multiple process modifications explored to establish single stage setup for BIW coating. Process capability and effectiveness of utilization was studied. The results were analyzed, and the comprehensive process chain was concluded and discussed for implementation.
B, Sivasankar, Selvam, Ganesan, Kannan, Muniya Gounder, voppuru, Naga Sheshank Reddy, Thiruppathi, R
Technical Paper
EXPERIMENTAL STUDY ON SS-304 SHEET METAL FOR BENDING PROCESS OPTIMIZATION USING RESPONSE SURFACE METHOD2021-28-026810/01/2021
In industry, productivity is based on various manufacturing processes. Bending the Sheet metal process is a type of forming process that has been used by the wide range in industries. There are several tangible and intangible factors affecting the production rate during the bending process. Spring back is one of the severe factors which affects the production rate, especially in stainless steel material. The spring back is mostly affected by material properties, sheet thickness, bending radius, die sizes and component geometry. In this paper, the spring back is studied by the effect of various parameters such as rectangle / oblong slots with varying pitch distance and without slots and bending time in the stainless steel material 304 grade in V-air bending machine. The experimental data are evaluated by using the Response Surface Method and conclusions are drawn. Finally found that explored results have the betterment of the production rate with connection to spring back. The study
NATARAJAN PhD, Balaji, SUBRAMANIAN, BALASUBRAMANI, KANAGARAJ, KANNAN, R, Soundararajan
Technical Paper
SM0001-TestSAE-PP-0045409/25/2021
Current automobile's auto-transmission has problems of defects and cost reduction because of welding process and very complicated assembly process due to individualized transmission piston and sealing components. Also, size and heavy weight of transmission piston components are the source of low mileage because they are made of aluminum, steel material. In this study, therefore, we perform structure design for piston sealing system which integrates piston and sealing material for automobile's lightweight auto-transmission. Also performed stress analysis through finite element analysis to secure required suitable strength when internal pressure is applied after assemble.
Mutagaana, Festo
Pre-Print Article
A Case study on Effect of subsequent operations on shotpeened Crown Wheel Pinion (Hypoid Gear set) & Compressive Residual Stress analysis2021-26-025209/22/2021
Abstract: The prime function of crown wheel pinion is to receive the power from Transmission & distribute to two-wheel Ends. Doing so these members will experience the tremendous Bending Fatigue. Shot peen is the one of the latest technologiesused to improve the bending Fatigue of the CWP. In this particular case- 6 CWP are taken for the Study to understand the effect of the operations after shot peen process. 3 Samples are named as Batch A, another 3 samples are named as Batch B. Both the batch CWP are shot peened. Then as a regular production Practice the Batch A CWP are process through Hard TurningAbrasive Lapping Hot Lubriting (Mn Phosphate)Fully Finish Ready for Assembly. Then Both the Batch A & batch B samples are taken for Residual Stress analysis using X-Ray Diffraction Technique. The measurement location is 50 microns below the surface. The results tabulated,found that Batch A samples shows decrease in Residual stress relatively to Batch B.This evident that post operations
Rao, Yathish
Technical Paper
RM13006 - Process Control MethodsAESQRM00620210909/07/2021
AS13100 AESQ Quality Management System Requirements for Aero Engine Design and Production Organizations Standard was created to replace customer specific quality requirements – leading to simplification and harmonization between engine manufacturer supply chains. AS13100 is supported by a series of 13 AESQ Reference Manuals (RM) that provide additional detail on certain subjects to describe the intent of the standard and to provide guidance on deployment. The Reference Manuals are designed to enable the supply chain to deploy the AS13100 requirements efficiently and effectively. The AESQ RMs provide case studies, guidance material, forms and checklists specific to each section of the standard to aid the user with implementation.
Aerospace Engine Supplier Quality Strategy Group
Best Practice
Method Recovers Metals from Electronic WasteTBMG-3959108/01/2021
Inspired by nature’s work to build spiky structures in caves, engineers have developed a method to recover precious metals from electronic waste. Using controlled applications of oxygen and relatively low temperatures, the engineers say they can de-alloy a metal by slowly moving the most reactive components to the surface, where they form stalagmitelike spikes of metal oxides. That leaves the least-reactive components in a purified, liquid core surrounded by brittle metal-oxide spikes.
Magazine Article
Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace VehiclesAS4461D-TEST-REC (Historical)07/23/2021
This standard is applicable to manual soldering and machine soldering processes utilizing controlled soldering devices, for electrical connections for wiring and cabling used in aerospace vehicles. Description of a component or device herein is not to be construed as authorizing the use of the component or device.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Technical Standard
Assembly and Soldering Criteria for High Quality/High Reliability Soldering Wire and Cable Termination in Aerospace VehiclesAS4461D (Current)07/23/2021
This standard is applicable to manual soldering and machine soldering processes utilizing controlled soldering devices, for electrical connections for wiring and cabling used in aerospace vehicles. Description of a component or device herein is not to be construed as authorizing the use of the component or device.
AE-8A Elec Wiring and Fiber Optic Interconnect Sys Install
Technical Standard
Recommended Practice for Processing and Handling Wire and Cable with Silver Plated Conductors and ShieldsARP6400 (Current)06/07/2021
This ARP specifies the recommended methods of handling silver coated conductors and shield, by the conductor fabricator, wireinsulator, distributors, harness or assembly houses, and OEM’s. Red Plague mitigation depends upon each link in the chain of supply handling the wire and cable properly.
AE-8D Wire and Cable Committee
Recommended Practice
Chord Method of Evaluating Surface Microstructural CharacteristicsARP1820C (Current)05/19/2021
This practice provides a method for evaluating microhardness and microstructure very close (0.002 inch (0.051 mm) or less) to the surface of a disk specimen. Specific accept/reject criteria for partial decarburization (3.7.1), inadvertent carburization/nitriding (3.7.3), total decarburization/intergranular oxidation (3.8), and other characteristics evaluated are to be found in the applicable specification where this ARP is referenced.
AMS E Carbon and Low Alloy Steels Committee
Recommended Practice
SAE TOMORROW TODAY: Cat MineStar Pushing Autonomy to New Levels1301505/17/2021
Caterpillar Inc., known globally for autonomous vehicle fleets, has hauled 3 billion tons of material to date. On this episode, Michael C. Murphy, Chief Engineer at Cat MineStar Solutions, shares how process, people and productivity, as well as the commitment to safety are working together to make this tremendous impact on the mining industry.
Hineman, Marcie
Podcast
Polishing Compound, Aircraft MetalAMS1650D (Current)05/06/2021
This specification covers a polishing compound for aircraft metals in the form of a liquid or paste.
AMS J Aircraft Maintenance Chemicals and Materials Committee
Material Specification
How 3D printing could add efficiency to EV power electronics21AUTP05_0805/01/2021
“Think production!” Perhaps that advice should be posted on the wall of every design office, R&D lab and advanced technology center in the auto industry. Although obeying that warning is clearly not cost-effective in some instances, others are ostensibly perfect to take their place in volume manufacture. An example is 3D printing (aka additive manufacturing, or AM), but despite a broadening scope that now embraces rapid prototyping and tooling by entire houses, it could do better in series production of auto components, particularly in the new world of EVs. Prof. Peter Wilson of the U.K.'s newly established Institute for Advanced Automotive Propulsion Systems (IAAPS) at the University of Bath, noted the growing adoption of high-speed SiC (silicon carbide) and other wide-band-gap semiconductor devices demonstrates the benefits that 3D printing could have in the production of EV inverters. “SiC devices offer so much opportunity to improve inverter performance,” Wilson said. “But system
Birch, Stuart
Magazine Article
Metal Powder Feedstock Size ClassificationsAMS7025-TEST-REC (Historical)04/22/2021
This specification covers particle size classifications and corresponding particle size distribution requirements for metal powder feedstock conforming to a classification.
AMS AM Additive Manufacturing Metals
Material Specification
Metal Powder Feedstock Size ClassificationsAMS7025 (Current)04/22/2021
This specification covers particle size classifications and corresponding particle size distribution requirements for metal powder feedstock conforming to a classification.
AMS AM Additive Manufacturing Metals
Material Specification
Aluminum Alloy, Castings 5.0Si - 1.2Cu - 0.50Mg (355.0-T51) Precipitation Heat TreatedAMS4210M (Current)04/22/2021
This specification covers an aluminum alloy in the form of castings.
AMS D Nonferrous Alloys Committee
Material Specification
Cast Aluminum Alloy Composite 4.6Cu - 3.4Ti - 1.4B - 0.75Ag - 0.27Mg (205.0/TiB2/3p-T7P) Investment Cast, Solution and Precipitation Heat TreatedAMS4471B (Current)04/22/2021
This specification covers a dilute aluminum/TiB2 metal matrix composite in the form of investment castings.
AMS D Nonferrous Alloys Committee
Material Specification
SAE TOMORROW TODAY: Bear Flag Robotics, Helping Farmers Improve Sustainability1300804/06/2021
Sustainable farming is within reach and Bear Flag Robotics is part of the collage of technology that's making it happen. On the latest episode, we spoke with Igino Cafiero and Aubrey Donnellan, Founders of Bear Flag Robotics, to discuss how the unique business model enables business and farming success. From their days at Carnegie Mellon to the present, the unique perspectives of Cafiero and Donnellan have helped build the Bear Flag Robotics business on diversity of thought, transparency and trust. Discover how they bring these same ideals to business relationships with farmers and how Bear Flag's technology plays a role in safety, productivity and sustainability.
Hineman, Marcie
Podcast
RM13006 - Process Control MethodsAESQRM00620210303/08/2021
AS13100 AESQ Quality Management System Requirements for Aero Engine Design and Production Organizations Standard was created to replace customer specific quality requirements – leading to simplification and harmonization between engine manufacturer supply chains. AS13100 is supported by a series of 13 AESQ Reference Manuals (RM) that provide additional detail on certain subjects to describe the intent of the standard and to provide guidance on deployment. The Reference Manuals are designed to enable the supply chain to deploy the AS13100 requirements efficiently and effectively. The AESQ RMs provide case studies, guidance material, forms and checklists specific to each section of the standard to aid the user with implementation.
Aerospace Engine Supplier Quality Strategy Group
Best Practice
Application of Selective Assembly as an Aerospace Design for Manufacturing and Assembly Principle for Effective Variation Management in Aerospace Assemblies2021-01-000503/02/2021
Aerospace engine parts are complex precision-engineered products with tighter assembly tolerances produced by conventional and non-conventional manufacturing processes. Variations in these manufacturing processes have to be controlled, process risks mitigated, and managed effectively, to facilitate the ease of aero-engine assembly to reduce overall variation and improve the assembly quality. One such technique is the application of the Selective Assembly as a Design for Manufacturing and Assembly (DfMA) tool. The paper details the methodology of Selective Assembly, its applications, benefits, and limitations in the aerospace industry along with a framework case study with a focus on ease of assembly and meeting the design intent of the assembly fit with the detailed study on the current traditional assembly process. The focus is to analyze the current challenges faced on the application of the Selective assembly of Aero-engine components through a case study on the development and
Rajamani, Mani Rathinam
Journal Article
Development of a Non-Parametric Robot Calibration Method to Improve Drilling Accuracy2021-01-000303/02/2021
The drilling of large quantities of repetitive holes during the manufacture of large aerospace components is often considered a key limiting factor with regards to production efficiency. Whilst the desire within aerospace is to use relatively cheap six axis robot arms with drilling end effector units, their poor accuracy remains an obstacle. Robot calibration presents a way of improving robot accuracy such that aerospace drilling tolerances can be met, without permanently committing metrology equipment to an automation cell during production. Extensive research has been conducted into robot calibration by correcting the kinematic model, known as parametric calibration. This method is highly complex, and calibrates the robot across the entire working volume. This is often not required in industrial drilling applications, as drilling routines are often contained within a smaller volume of the robot reach. In this paper, a non-parametric method of robot calibration is proposed. This
Scraggs, Chris, Smith, Thomas, Sawyer, Daniela, Davis, Matthew
Journal Article
Application of Metrology, Statistics, Root Cause Analysis, and Cost of Quality to Enable Quality Improvements and Implementation of Statistical Process Controls for Acceptance of Large Complex Assemblies2021-01-002503/02/2021
For new aircraft production, initial production typically reveals difficulty in achieving some assembly level tolerances which in turn lead to non-conformances at integration. With initial design, tooling, build plans, automation, and contracts with suppliers and partners being complete, the need arises to resolve these integration issues quickly and with minimum impact to production and cost targets. While root cause corrective action (RCCA) is a very well know process, this paper will examine some of the unique requirements and innovative solutions when addressing variation on large assemblies manufactured at various suppliers. Specifically, this paper will first review a completed airplane project (Project A) to improve fuselage circumferential and seat track joins and continue to the discussion on another application (Project B) on another aircraft type but having similar challenges. The use of Project A and B is used here to ensure proprietary protection of internal and supplier
Hall, Thomas D.
Journal Article
SUPPLIER EYE21AUTP03_0603/01/2021
Momentum has been building for several years. Industry executives and analysts have been outlining the impact on the automotive industry of an all-electric light-vehicle future. Such a future still seemed distant for many. Would consumers embrace the propulsion shift to EVs? Would battery costs decline enough to achieve undeniable cost parity, or even cost advantage, compared with combustion-engine products? And could the charging infrastructure handle all these EVs in the car parc? All are great questions with varying levels of confidence as to the eventual outcome. To EV or not to EV?
Magazine Article
Creating High-Precision Glass for NIR LasersTBMG-3863303/01/2021
Erbium (Er) doped phosphate glass exhibits many beneficial properties, which has led to an increased demand in recent years for Er:glass lasers for applications as wide-ranging as laser rangefinding, long-distance communications, dermatology, and laser-induced breakdown spectroscopy (LIBS). Erbium fiber amplifiers enable rapid global communication in the transpacific cable between Hong Kong and Los Angeles, Er:glass laser rangefinders are increasingly used in defense applications and reconnaissance, and Er:glass aesthetic lasers are gaining traction for removing scarring and even treating hair loss caused by androgenetic alopecia.
Magazine Article
CES 2021: GM creates BrightDrop electrified delivery and logistics company21AUTP02_0902/01/2021
During her CES 2021 keynote in January, GM Chairman and CEO Mary Barra announced the creation of a new logistics company called BrightDrop. The new business will create an ecosystem of electrified products, software and services for first-to-last-mile delivery. This includes EPI, a new electric pallet to shuttle packages, as well as a new commercial delivery truck based on GM's Ultium battery platform, the EV600. The first customer of the new business will be FedEx Express. According to GM, BrightDrop's electrified solutions were created to help businesses reduce costs, maximize productivity, improve employee and freight security and support sustainability efforts. The EP1 pallet will be available in early 2021 and the EV600 light commercial vehicle (LCV) is expected to be on the road by late 2021. The EV600 is GM's first commercial application of its Ultium battery platform and the truck will feature both Level-2 and DC fast-charging capabilities.
Seredynski, Paul
Magazine Article
Manufacturing Ultra-Thin Camera LensesTBMG-3849002/01/2021
In the future, camera lenses could be thousands of times thinner and significantly less resource-intensive to manufacture using new technology for making the artificial materials known as metasurfaces. These materials consist of a multitude of interacting nanoparticles that together can control light. Meta-surfaces can be used for optical components in portable electronics, sensors, cameras, or space satellites. The new technology for making such planar surfaces is based on a plastic that is already used today to create other microstructures.
Magazine Article
Aircraft Electrical Voltage Level DefinitionsAIR7502 (Current)01/27/2021
The scope of this report will document the various voltage levels and provide a rational for each level as discussed and agreed to in the AE-7 committee.
AE-7C Systems
Information Report
Essentials of PCBA Cleaning for WearablesTBMG-3815312/01/2020
Wearable healthcare is on the rise. In fact, the wearable medical devices market size was valued at over USD 9.0 billion in 2018 and is expected to witness 39.4 percent CAGR from 2019 to 2025. The demand for digital wellness, remote monitoring, and diagnostics means an increasing requirement to produce complex miniature electronic components with ever-tighter tolerances. This brings with it printed circuit board assembly (PCBA) cleaning challenges that must be addressed at the design stage in order to ensure reliability. This article discusses how PCBA cleaning can be incorporated into the planning and production of wearables and the essential methods to be used.
Magazine Article
LEAD-FREE SOLDER VALIDATION TEST PLANUSCAR40-2 (Current)11/19/2020
This guideline is applicable to existing lead solder production products that will change to lead-free solder processes to meet the ELV Directive 2000/53/EC Annex II, exemption 8B requirements. This guideline is applicable to similar products used by multiple OEM's that have the same manufacturing processes / equipment. The intent is to streamline the supplier’s environmental testing via common qualification to reduce timing, quantities, and costs.
USCAR
Specification
Fluid, Aircraft Deicing/Anti-Icing, SAE Type IAMS1424R (Historical)11/18/2020
This foundation specification (AMS1424R) and its associated category specifications (AMS1424/1 and AMS1424/2) cover a deicing/anti-icing material in the form of a fluid.
G-12ADF Aircraft Deicing Fluids
Material Specification
Fluid, Aircraft Deicing/Anti-Icing, SAE Type IAMS1424R-TEST-REC (Historical)11/18/2020
This foundation specification (AMS1424R) and its associated category specifications (AMS1424/1 and AMS1424/2) cover a deicing/anti-icing material in the form of a fluid.
G-12ADF Aircraft Deicing Fluids
Material Specification
Single-Use Applications Maximize Biomanufacturing AgilityTBMG-3806611/01/2020
Biopharmaceutical manufacturing is changing. With the rise of biologics and personalized medicine, the industry is appreciating the single-use manufacturing style. Instead of large-scale production processes, manufacturers are finding it pays to be agile — which is why many are increasingly adopting single-use technologies to turn over new products and batches quickly and efficiently. Single-use technologies utilize disposable bioprocessing equipment in place of traditional stainless steel. By eliminating the time-consuming clean-in-place (CIP) and steam-in-place (SIP) processes between batches, single-use technologies cut down on the costs of labor, materials, and utilities — all while shortening time to market.
Magazine Article
Taking Benchtop Fluid Dispensing to a New Level of Process ControlTBMG-3807611/01/2020
Pneumatic benchtop fluid dispensers encompass a range of models that can accommodate specific fluid application processes with a wide scope of functionality. The latest benchtop dispensers provide a high degree of process control, capable of dispensing adhesives, solder pastes, and all other assembly fluids with high consistency. Handling fluid dispensing of dots, beads, and fills under a broad range of conditions, these units are equipped with multiple capabilities to refine the dispensing process. Features such as 0–100 psi air pressure regulation, timed-shots, vacuum control to keep thin fluids from dripping, digital time/pressure displays, and electric foot pedals help operators maintain process control.
Magazine Article
Controlling Defects in 3D PrintingTBMG-3781410/01/2020
Additive manufacturing's ability to yield parts with complex shapes and minimal waste is currently limited by one critical challenge: controlling defects in the process that can compromise the performance of 3D-printed materials. Researchers have developed a method to use temperature data at the time of production to predict the formation of subsurface defects, so they can be addressed then and there.
Magazine Article
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