Several unique technologies are available to error-proof connector assembly. Using lamps, lasers and real-time video, these products guide assemblers step-by-step through the assembly process, guaranteeing correct insertion.
Automakers are often the driving force behind the latest product and process innovations in assembly. Case in point: European automakers have been using flow drilling screws since 1996 to assemble body panels and chassis made of aluminum and thin materials-which continue to gain favor to make cars lighter.
Evolving technology, such as carbon nanotubes, fiber optics and printed electrical systems, may provide the backbone of future electrical distribution systems in cars, trucks, locomotives, aircraft and other vehicles.
Recently, a well-known European hybrid car manufacturer asked Satrotec AG to produce a high-voltage wiring system inside an encapsulated electronic enclosure. The automaker specified 180 milliliters of proportioned and mixed polyurethane encapsulant be automatically and accurately dispensed into the electronic enclosure.
Recently, Alfmeier Präzision AG sought a way to improve the performance of lumbar-support devices they supply for seats in luxury cars. The problem involved the devices’ subsystem, which was damaging adjacent seat foam and failing prematurely.
Cummins Inc. faced a challenge when developing its off-highway Tier 3 QSX engine a few years ago. The manufacturer had to find a way to keep the engine’s exhaust manifold joints secure enough to withstand severe vibration, joint fatigue and temperature extremes present in industrial field use.
When Prüfrex received a major new contract to produce small engine ignition control systems for forestry and garden machines, the company decided to replace its existing semiautomated production line with a faster, more powerful alternative.
Watch case component connections are machined at Titan Industries' manufacturing facility in Tamil Nadu. Until recently, the components were loaded manually into machines. However, manual loading significantly limited production speed, so Titan automated the process with a robot.
Today, just about every square inch of a typical automobile is crammed full of electronic components. Microprocessors, sensors, connectors and other increasingly smaller and more robust devices are inside doors, under seats, behind dashboards, inside tires and under hoods.
In his recent State of the Union address, President Obama challenged Americans to be more innovative. That means developing new materials, new products and new production processes. To tackle that challenge, manufacturing engineers must harness the power of “smart assembly” tools and systems.
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