https://www.assemblymag.com/rss/2129-featured-stories en-us camilloj@bnpmedia.com (Jim Camillo) Every manufacturer has one want and many needs. The want is universal, to be the leader in its industry or area of specialty. The needs are individual, and may concern issues as diverse as increasing capital, upgrading technology, expanding plant size or hiring more assemblers.

]]> http://www.assemblymag.com/articles/95395 Fri, 10 Jan 2020 09:43:00 -0500 https://www.assemblymag.com/articles/95395-do-you-really-need-a-vision-system Do You Really Need a Vision System? Camera-based vision systems are used in many industries. Here, a camera with a ring light performs inspection on a carton making machine. Photo courtesy Balluff Inc. Do You Really Need a Vision System? The BVS SC SmartCamera accurately detects machine codes, text or serial numbers, and assists robots in position finding. Photo courtesy Balluff Inc. Do You Really Need a Vision System? In this application, a smart camera makes sure that electronics connectors are within tolerance. Photo courtesy Cognex Corp. http://www.assemblymag.com/articles/95139 Mon, 12 Aug 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95139-six-reasons-for-capital-equipment-disaster 1 To ensure the success of a capital equipment project, engineers should choose a systems integrator wisely. Photo courtesy ATC Automation 2 A major reason for capital disasters is a lack of parts for proper debug and runoff. Photo courtesy ATC Automation 4 Engineers must be given enough time to complete an automation project. Haste makes waste. Photo courtesy ATC Automation 5 The best strategy for a runoff is to get your team involved in establishing the criteria for equipment acceptance. Photo courtesy Cincinnati Test Systems Inc. http://www.assemblymag.com/articles/95138 Fri, 09 Aug 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95138-the-challenge-of-automating-a-manual-process auto Robots are great tools for automating manual processes. However, engineers may not always have the knowledge or the time to deploy them successfully. Photo courtesy Omron Corp. 2 Some manual processes, such as filling and handling bottles, have been automated for years and are relatively simple to automate. Other processes, such as pushing surgical tubing onto a barbed fitting, are much more difficult to automate. Photo courtesy Valin Corp. 3 A variety of components are needed to automate a manual process. Illustration courtesy Valin Corp. 4 Even simple assembly processes, such as dispensing, can be more complex to automate than at first glance. Photo courtesy Parker- Hannifin Corp. http://www.assemblymag.com/articles/95137 Thu, 08 Aug 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95137-light-fixation-revolutionizes-two-part-epoxies 1 This graph shows the front peel strength of DELO-Duopox DB8989 on sand-blasted aluminum after exposure to UV light at 1,000 mW/cm². Photo courtesy DELO Industrial Adhesives 2 Light-fixable two-component epoxies maintain good strength levels after aging tests. Photo courtesy DELO Industrial Adhesives 3 The Young’s modulus of DELO-Duopox DB8989 is comparable in the areas exposed to light and shaded from light, even after challenging aging simulations. Photo courtesy DELO Industrial Adhesives 4 Dual-curing two-component epoxies have many advantages compared with conventional one- and two-component chemistries. Photo courtesy DELO Industrial Adhesives 5 UV-curing two-component epoxies reach green strength in just a few seconds, as opposed to an hour with many conventional epoxies. That can be a great advantage when bonding magnets in electric motors. Photo courtesy DELO Industrial Adhesives http://www.assemblymag.com/articles/95136 Wed, 07 Aug 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95136-using-labels-to-optimize-5s 1 Color coding labels can add another level of organization to items. Photo courtesy Avery Products Corp. 2 A good inspection label will include areas for marking the date and person who conducted the inspection. Photo courtesy Avery Products Corp. 3 Adding bar codes to labels can further improve efficiency, since scanning a bar code is much faster and more accurate than manual data entry. Photo courtesy Avery Products Corp. 4 Avery’s new Surface-Safe sign and ID labels are designed to stick securely yet remove cleanly without damaging the surface or leaving an adhesive residue. Photo courtesy Avery Products Corp. 5 Surface-Safe sign labels can be used on walls, doors and glass, without worrying about damaging their surfaces. The Surface-Safe ID labels are designed to be used on plastic and metal surfaces, such as machinery, racks or totes, even if their surfaces are highly textured. Photo courtesy Avery Products Corp. camilloj@bnpmedia.com (Jim Camillo) http://www.assemblymag.com/articles/95135 Tue, 06 Aug 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95135-whats-new-with-orbital-and-radial-forming 1 In orbital forming, the peen moves in an orbital path and displaces a minute quantity of material with each rotation of the forming head until forming is complete. Photos courtesy Orbitform Group 2 Designed for a Tier 1 automotive supplier, this orbital forming unit features dual-opposed SV315 powerheads and an in-process torque precision system. The two heads work independently to form the main pivot point of a steering system. Photo courtesy Orbitform Group 3 The compact ER15 electric power module features two servodriven motors and efficiently performs radial and orbital forming. Photo courtesy BalTec Corp. webera@bnpmedia.com (Austin Weber) http://www.assemblymag.com/articles/95134 Mon, 05 Aug 2019 09:45:00 -0400 https://www.assemblymag.com/articles/95134-building-better-batteries 1 Screwdriving plays an important role in producing battery enclosure assemblies. Photo courtesy Akasol AG 2 Key components of automotive battery packs include battery modules, cooling systems, power electronics and battery management systems. Photo courtesy Volkswagen AG 3 During the next decade, advanced batteries will be mass-produced for a wide variety of new applications on land, sea and air. Photo courtesy Akasol AG 4 To reduce costs and boost throughput, robots and other types of automation are essential. Photo courtesy Siemens AG http://www.assemblymag.com/articles/95081 Mon, 22 Jul 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95081-how-well-do-you-know-your-crimping-process 1 Surprisingly, introducing the wrong materials into the production stream is a common cause of defects and rework. Is your system set up to eliminate the possibility of employee error? Photo courtesy Schäfer Group 2 Crimp force monitoring, crimp height measurement and pull force testing are the primary tools in a harness assembler’s quality assurance program. Photo courtesy C&S Technologies 3 Applicator setup is critical for producing quality crimps. Has the applicator been prepared for production? Was it inspected after the last production run? Photo courtesy Schäfer Group 4 By itself, a crimpforce monitor will not solve your crimping problems nor will it guarantee nonconforming crimps. Photo courtesy Applitek sprovierij@bnpmedia.com (John Sprovieri) http://www.assemblymag.com/articles/95080 Fri, 19 Jul 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95080-processing-thick-cables 1 The growth in electric vehicle sales has harness assemblers stocking up on equipment specifically to cut, strip and crimp the large-diameter wire and cable needed to connect motors and batteries. Photo courtesy Siemens 2 The MegaStrip 9650 automatically cuts and strips a wide range of large cables up to 35 millimeters in diameter. Photo courtesy Schleuniger Inc. 3 The EPS 15000 semiautomatic electric press was designed to crimp individual terminals on wires with large cross-sections. Photo courtesy the Schaefer Group 4 Ultrasonic welding is one option for terminating large-diameter wire. Photo courtesy Telsonic Ultrasonics Inc. 5 Terminals, or “lugs,” for large-diameter wire are typically supplied as loose parts, rather than daisy-chained on a reel. Photo courtesy the Schaefer Group 6 The main challenge when feeding thick wire and cable is to keep it straight. Prefeeders solve this problem. Photo courtesy Schleuniger Inc. 7 camilloj@bnpmedia.com (Jim Camillo) http://www.assemblymag.com/articles/95079 Wed, 17 Jul 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95079-handheld-wire-crimping-tools 1 The pliers-style Duo hand tool crimps single and twin ferrules, and features a rotating die for front or side entry. Photo courtesy Phoenix Contact 2 The WA22LC-X1 pneumatic indent crimper is capable of crimping size 20 and smaller contacts onto 32 to 20 AWG wire. Photo courtesy Daniels Manufacturing Corp. 3 K-Frame manual crimpers feature a scissor-action ratchet and produce a maximum crimp force of 2,250 pounds. Photo courtesy Pressmaster Inc. 4 Many handheld manual tools come with numerous dies that easily change out and accommodate different wire sizes, connectors, crimp configurations and shapes. Graphic courtesy AutomationDirect http://www.assemblymag.com/articles/95077 Mon, 15 Jul 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95077-how-to-effectively-deploy-cobots 1 The ideal application for a cobot is one in which it functions as a rote assistant to a human worker. Photo courtesy Ultra Tech Automation 2 There are trade-offs between traditional robots and cobots. Cobots may not provide the throughput that a traditional robot can deliver for your specific application. Photo courtesy Ultra Tech Automation 3 In many cases, the decision to use a cobot turns on a company’s assessments of floor space, line speed. Cobots are often a good choice when people must be able to access a machine to restock parts. Photo courtesy Ultra Tech Automation 4 Useful applications for cobots include palletizing, small-parts assembly, machine tending, packaging, polishing, machine tending and parts inspection. Photo courtesy Ultra Tech Automation 5 In many cases, an application is best be solved with a conventional robot and a well-engineered process, avoiding the compromises sometimes associated with cobots. Photo courtesy Ultra Tech Automation sprovierij@bnpmedia.com (John Sprovieri) http://www.assemblymag.com/articles/95076 Fri, 12 Jul 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95076-automated-dispensing-in-aerospace 1 A common application for automated dispensing in aerospace is sealing the edges of honeycomb panels and components, such as brackets, made carbon-fiber composites. Photo courtesy ViscoTec 2 The aerospace industry has lagged behind the automotive industry in terms of automated dispensing. Photo courtesy Bombardier Inc. 3 Designed for sealant dispensing applications in aerospace manufacturing, the robot-mounted JetStream system features an articulating holder that opens to accept cartridges of premixed sealant. Its built-in volumetric dispense valve assembly eliminates material supply hoses and increases the accuracy of bead volume and placement. Photo courtesy Nordson Sealant Equipment 4 Since honeycomb panels are mostly air, threaded fasteners are not an option for attaching things like shelves, bins or brackets—unless parts of the honeycomb are filled with a lightweight epoxy first. Photo courtesy ViscoTec-America Inc. 5 The process of dispensing sealant onto adjoining parts is often automated. Photo courtesy Henkel 6 Adhesives are used in conjunction with mechanical fasteners to attach stringers to wing skins. Photo courtesy Bombardier Inc. camilloj@bnpmedia.com (Jim Camillo) http://www.assemblymag.com/articles/95075 Wed, 10 Jul 2019 08:00:00 -0400 https://www.assemblymag.com/articles/95075-tool-balancers-and-support-arms 1 Since 2009, GCI has produced custom carbon fiber torque and manipulator arms. The company makes carbon fiber arms up to 20 feet long with torque ratings of 30 to 7,500 newtonmeters. Photo courtesy GCI 2 Last year, an off-highway equipment manufacturer installed 24 AR40 arms on two assembly lines to help workers perform nutrunning more ergonomically. Graphic courtesy FlexArm 3 Mountz Inc. offers several types of tool balancers. The MZ series of zero-gravity balancers includes 15 models with strokes from 19 to 82 inches, and capacities from 1.1 to 264 pounds. Photo courtesy Mountz Inc. 4 The AcraDyne Gen IV Ace controller provides smart-arm operators with process visualization. Photo courtesy AIMCO Global webera@bnpmedia.com (Austin Weber) http://www.assemblymag.com/articles/95074 Tue, 09 Jul 2019 13:13:00 -0400 https://www.assemblymag.com/articles/95074-additive-manufacturing-the-quest-for-automation 1 Next-generation additive manufacturing applications will feature fast machines tended by automated guided vehicles. Photo courtesy 3D Systems Inc. 2 Additive manufacturing is traditionally a manual process that requires many steps. Photo courtesy Voodoo Manufacturing Inc. 3 Collaborative robots will play a key role in automated additive manufacturing. Photo courtesy Fast Radius Inc. 4 Automation will help improve throughout in post-processing applications that have traditionally been slow and time-consuming. Photo courtesy Ford Motor Co. 5 This robot tends a cluster of more than 25 printers. Photo courtesy Voodoo Manufacturing Inc. 6 These high-speed, high-volume printers were designed with automation in mind. Photo courtesy Desktop Metal Inc. 7 In the future, automated material handling and robots will support a network of connected printers, ovens and other additive manufacturing equipment. Photo courtesy Daimler AG 8 This machine features automated material feeders and can print either metal or plastic parts. Photo courtesy AIM3D http://www.assemblymag.com/articles/95039 Fri, 07 Jun 2019 09:00:00 -0400 https://www.assemblymag.com/articles/95039-surface-preparation-and-medical-silicone-adhesives 1 The contact angle of a drop of water on the substrate surface helps quantify the wettability of the surface. In general, if the contact angle is below 90 degrees, the material has high surface energy and provides good surface wettability. If the contact angle is greater than 90 degrees, the material has low surface energy, with a greater likelihood of adhesion failure due to blank spots on the substrate surface where no adhesive is present. Illustration courtesy Avantor 2 Medical device manufacturers often use silicone adhesives to assemble products such as catheters, pacemakers and cochlear implants. Photo courtesy Avantor 3 Cleaning the surface of the substrates with isopropyl alcohol significantly improved the contact angle. Source: Avantor 4 The researchers assessed the effect of surface treatments on bonding Pellethane 2363 80A. Significant improvements were shown with surface cleaning alone, and even more so when primers were used. MED-162 primer provided the largest improvement in adhesion for both silicone adhesives tested. Source: Avantor 5 The researchers also assessed the effect of surface treatments on bonding Pellethane 2363 55D. Although slight improvements in peel force were shown with surface cleaning alone, significant improvements were shown through the use of both primers. The combination of MED-160 primer and MED-1137 adhesive outperformed all other pairings. Source: Avantor 6 Silicone adhesives are available in one- and two-part formulations. Photo courtesy Avantor 7 Silicone adhesives can be supplied in a variety of packaging. Photo courtesy Avantor camilloj@bnpmedia.com (Jim Camillo) http://www.assemblymag.com/articles/95038 Thu, 06 Jun 2019 09:00:00 -0400 https://www.assemblymag.com/articles/95038-laser-sensors-and-automated-assembly 1 Compact LM laser sensors accurately measure the thickness and height of moving targets that have varying colors and reflectivity. Photo courtesy Banner Engineering Corp. 2 The handheld HS763 sensor measures gaps and flush on translucent, shiny or opaque surfaces around vehicle doors, headlights, taillights, windows and chrome while the car is advancing on a moving assembly line. Photo courtesy Origin Technologies Corp. 3 A 3D laser profile sensor, the Gocator 2512 scans glass, polished metals and plastic, and a wide variety of other specular materials and surfaces as they move on a conveyor. Photo courtesy LMI Technologies Inc. 4 The BOS21M series of photoelectric sensors offers background suppression, ensuring reliable defect and part detection regardless of the target’s surface, color and material. Photo courtesy Balluff Inc. sprovierij@bnpmedia.com (John Sprovieri) Whether it's a car or a computer, a toy or a toaster, almost every assembled product has at least a few threaded fasteners. Indeed, 62 percent of ASSEMBLY's readers use threaded fasteners of one form or another to assemble their products.

]]> http://www.assemblymag.com/articles/95037 Wed, 05 Jun 2019 09:00:00 -0400 https://www.assemblymag.com/articles/95037-whats-new-with-power-tools 1 Thanks to its 60-volt DEWALT Flexvolt battery, the B44L is one of the most powerful cordless nutrunners on the market. Photo courtesy Stanley Assembly Technologies 2 CellCore cordless assembly tools can run 500,000 cycles between maintenance. Photo courtesy Cleco Production Tools 3 Available in pneumatic and electric versions, the Nanomat screwdriver is designed to install very small screws Photo courtesy DEPRAG Inc. 4 The AcraDyne high-torque cordless tool has a battery-driven, two-speed torque multiplier for torques ranging from 90 to 4,000 newtonmeters. Photo courtesy AIMCO 5 The Du-Pas TDIS Series of pneumatic pulse tools shut-off automatically when the set torque has been reached. Photo courtesy TorqTec 6 The Yokota YS-e cordless pulse tool can capture torque and angle data and transmit it wirelessly to a controller. Photo courtesy Ingersoll Rand 7 Electronics for measuring torque and angle of rotation have been integrated directly into the Nexo cordless nutrunner. Photo courtesy Bosch Rexroth Corp. http://www.assemblymag.com/articles/95031 Tue, 04 Jun 2019 10:35:00 -0400 https://www.assemblymag.com/articles/95031-choose-the-best-conveyor-for-assembly 1 Belt media are ideal for lighter payloads and can transfer materials over long distances at high speeds. Photo courtesy Bosch Rexroth Corp. 2 Flat-top chains can support heavy payloads, and their side-flexing design makes them ideal for use with curves and for maintaining leading-edge pallet orientation. Photo courtesy Bosch Rexroth Corp. 3 Roller chains can be used in the most challenging environments. The power-and-free design creates a low-friction surface, allowing roller chains to convey heavy payloads. Photo courtesy Bosch Rexroth Corp. 4 Powered roller conveyors have the highest payload capacities. They’re also very quiet and require little maintenance. Photo courtesy Bosch Rexroth Corp. 5 When the conveying requirements include high speed and high positioning accuracy, a relatively new type of conveyor system, based on linear motor technology, can fit the bill. Photo courtesy Bosch Rexroth Corp. webera@bnpmedia.com (Austin Weber) http://www.assemblymag.com/articles/95029 Mon, 03 Jun 2019 15:11:00 -0400 https://www.assemblymag.com/articles/95029-carbon-fiber-composites-grow-in-popularity Carbon-Fiber Composites Grow in Popularity This carbon-fiber composite rear wall structure is bonded to an aluminum body structure. Photo courtesy Audi AG Carbon-Fiber Composites Grow in Popularity Carbon-fiber composites are an increasingly popular lightweighting option in the auto industry. Illustration courtesy General Motors Carbon-Fiber Composites Grow in Popularity Fasteners are used to attach some carbon-fiber composite parts to dissimilar materials. Photo courtesy BMW AG Carbon-Fiber Composites Grow in Popularity Structural auto parts made from carbon-fiber composites include B and C pillars, rear walls, roof arches and tunnels. Illustration courtesy Audi AG sprovierij@bnpmedia.com (John Sprovieri) http://www.assemblymag.com/articles/94987 Thu, 16 May 2019 08:00:00 -0400 https://www.assemblymag.com/articles/94987-manufacturing-fact-vs-science-fiction 1 While it might not be a true “lights out” operation, Festo’s state-of-the-art distribution and manufacturing center in Mason, OH, is equipped with a highly automated order-picking system that operates with little human input. Photo courtesy Festo Corp. 2 In James Cameron’s classic movie “Aliens,” Lt. Ellen Ripley dons a heavy-duty robotic exoskeleton to combat the alien queen. Photos courtesy 20th Century Fox 3 While engineers are a long way from developing an electromechanical suit that can enable a person to lift hundreds of pounds, several companies have introduced exoskeletons that help reduce strain and fatigue on the assembly line. Photo courtesy of Comau 4 Scientists have yet to create a machine that can produce chocolate cake and ice cream sundaes on demand, like the “Star Trek” replicator.Photo courtesy CBS Corp. 5 However, modern additive manufacturing technologies can mass-produce parts for cars, jets and medical devices. Photo courtesy Stratasys. 6 Manufacturers are increasingly using AGVs to transport parts and assemblies throughout a factory. Photo courtesy Red Viking http://www.assemblymag.com/articles/94986 Wed, 15 May 2019 08:00:00 -0400 https://www.assemblymag.com/articles/94986-iot-promises-a-future-of-guaranteed-outcomes 1 Jason Toschlog tests the current version of Flexware Innovation’s parking lot sensor. Flexware’s partner on this project has already ordered 10,000 units. Photo by Michael E. Fitzgerald 2 Tenants at the Indiana IoT Lab can mock up their designs on site at the 1st Maker Space, which provides laser cutters, a 3D printer, oscilloscopes and even a wood shop. Here, 1st Maker’s president, Kim Brand, shows off some of the electrical components he keeps on hand for tenants. Photo by Michael E. Fitzgerald 3 Mike Flockenhaus shows off SteadyServ Technologies’ smart scale, which monitors the weight of beer kegs to generate consumption data for what SteadyServ calls Kegonomics. Photo by Michael E. Fitzgerald 4 Jason Pennington flips through the Indiana IoT Lab’s inaugural edition of its State of IoT report. The 90-page report was released during an open house the lab held to celebrate its first anniversary on March 13. Photo by Michael E. Fitzgerald 5 Self-driving cars, like the Voyage G2, will communicate constantly with surrounding vehicles and with sensors built into roads, bridges and buildings. Photo courtesy Voyage 6 These coffee makers come with an app that allows consumers to schedule brews, monitor status, change settings, and receive notifications on Apple iOS and Android devices. Photo courtesy Smarter Applications Ltd. 7 The IoT is creating an expectation that devices will communicate with each other and “flow” as they interact with people in a space. “When I walk up to the house, the lock unlocks, the lights turn on, the security turns off, and immediately classical music is on because that’s what I like to happen when I come home,” says Lee Odess, the vice president for solution providers at Allegion. Photo courtesy Allegion 8 Caterpillar has begun outfitting its heavy equipment with sensors and embedded connectivity. Data gathered by the technology helps customers manage their fleets—and it helps Caterpillar’s engineers design better tractors and engines. Photo courtesy Caterpillar Inc. http://www.assemblymag.com/articles/94985 Tue, 14 May 2019 08:00:00 -0400 https://www.assemblymag.com/articles/94985-workforce-development-in-the-era-of-industry-40 1 Rockwell and ManpowerGroup are collaborating to train veterans for high-tech jobs. Photo courtesy ManpowerGroup 2 When transitioning a manufacturing workforce to new technology, it’s important to retain the knowledge of the processes from the workers who do them and use that knowledge to build new systems. Photo courtesy Schneider Electric 3 “Technology won’t displace work, it will reinvent it,” says Jason Tyszko, vice president of the Center for Education and Workforce of the U.S. Chamber of Commerce Foundation. Photo courtesy Universal Robots 4 A growing number of manufacturers are reviving a tried-and-true concept: the apprenticeship. Photo courtesy STIHL 6 New technology will redefine certain manufacturing roles in both name and skill requirements. Photo courtesy BMW sprovierij@bnpmedia.com (John Sprovieri) http://www.assemblymag.com/articles/94984 Mon, 13 May 2019 08:00:00 -0400 https://www.assemblymag.com/articles/94984-generative-design-software-is-transforming-the-design-process 1 General Motors used Autodesk’s generative design software to create a new seat bracket for an electric vehicle. Photo courtesy Autodesk 2 Generative design can look at different materials and manufacturing processes and come up with multiple solutions to a problem. Each design will solve the problem, but they might all be very different. Photo courtesy Autodesk 3 Engineers at Lightning Motorcycles used generative design software to design the swing arm for the new LS-218 electric motorcycle. Engineers wanted the design to be optimized for both weight and strength. The software recommended a part produced through additive manufacturing. Photo courtesy Autodesk 4 Engineers at Lightning Motorcycles used generative design software to design the swing arm for the new LS-218 electric motorcycle. (It’s the blue part in the photo.) Engineers wanted the design to be optimized for both weight and strength. The software recommended a part produced through additive manufacturing. Photo courtesy Autodesk 5 Generative design software is not CAD software, but an adjunct to it. Photo courtesy Siemens Digital Industries Software Inc. 6 Engineers at Stanley Black & Decker used generative design software to redesign a hydraulic crimping tool used by electrical workers. Photo courtesy Autodesk 7 Generative design cannot replace the judgement of engineers. Rather, it presents a series of equally viable design options to choose from based on their inputs. It’s up to engineers to decide which option best suits the needs of their project and their company’s manufacturing capabilities. Photo courtesy Siemens webera@bnpmedia.com (Austin Weber) http://www.assemblymag.com/articles/94983 Fri, 10 May 2019 08:00:00 -0400 https://www.assemblymag.com/articles/94983-assembly-plants-at-the-forefront-of-industry-40 1 “Lighthouse” factories focus on augmenting the operator and empowering the workforce. Photo courtesy BMW AG 2 Factories of the future will feature advanced technology such as digital twins. Photo courtesy BMW AG 3 Data analytics plays a key role in the day-to-day operation of BMW’s Regensburg plant. Photo courtesy BMW AG 4 An advanced operating system enables Fast Radius to collect and analyze data at every step of the additive manufacturing process. Photo courtesy Fast Radius Inc. 5 Industry 4.0 technologies such as collaborative robots enable smart factories to be extremely flexible. Photo courtesy Fast Radius Inc. 6 By creating digital copies of each customer’s specifications, Phoenix Contact has cut production time by 30 percent. Photo courtesy Phoenix Contact GmbH & Co. 7 Because of Industry 4.0 technology, complex production processes are easier to manage and optimize. Photo courtesy Phoenix Contact GmbH & Co. 8 Phoenix Contact can produce batch sizes of one at the same low cost as traditional mass-production processes. Photo courtesy Phoenix Contact GmbH & Co. 9 Data analytics technology enables employees to make better decisions on the plant floor. Photo courtesy Schneider Electric 10 Schneider Electric’s Le Vaudreuil plant uses state-of-the-art technology to improve productivity and streamline operations. Photo courtesy Schneider Electric Assembly Plants at the Forefront of Industry 4.0 Siemens’ flagship plant in Amberg, Germany, was the blueprint for its factory in Chengdu, China. Photo courtesy Siemens AG 13 Siemens employees check quality after each step of the production process. Photo courtesy Siemens AG sprovierij@bnpmedia.com (John Sprovieri) http://www.assemblymag.com/articles/95001 Thu, 09 May 2019 09:00:00 -0400 https://www.assemblymag.com/articles/95001-new-robots-grippers-unveiled-at-automate-2019 1 FANUC’s new FIELD system offers engineers an open platform that collects machine data and monitors the operating status of their manufacturing equipment in real time. Photo courtesy FANUC America 2 The new DHEF adaptive gripper can hold a range of shapes and unaligned objects. It can even hold several objects at once. Photo courtesy Festo Corp. 3 The Single-Arm YuMi is ABB’s most agile and compact collaborative robot. Photo courtesy ABB Inc. 4 Operators can teach Omron’s new TM Series cobot with hand-guidance. There’s no need for software. Photo courtesy Omron Automation Americas webera@bnpmedia.com (Austin Weber) http://www.assemblymag.com/articles/94982 Thu, 09 May 2019 08:00:00 -0400 https://www.assemblymag.com/articles/94982-lights-out-automation-fact-or-fiction 1 Today, many automotive body shops are close to being lights-out operations. Photo courtesy Ford Motor Co. 3 Lights-out factories will probably remain a goal of manufacturing engineers for years to come. Photo courtesy Fraunhofer 4 The recent advent of collaborative robots has eliminated traditional boundaries between humans and machines. Photo courtesy Fraunhofer 5 Oliver Evans created the world’s first continuous production line in 1784. Illustration courtesy Society for Industrial Archeology 9 The pure definition of “lights out” refers to a fully automated facility where human hands never touch a product during the entire manufacturing process. Photo courtesy Changying Precision Technology Co. http://www.assemblymag.com/articles/95000 Wed, 08 May 2019 09:00:00 -0400 https://www.assemblymag.com/articles/95000-americas-most-destructive-industrial-fire 1 On Aug. 12, 1953, fire destroyed GM’s state-ofthe- art transmission assembly plant in Livonia, MI. Photo courtesy General Motors Corp. 2 Causing $50 million in damage (almost $500 million in today’s dollars), the fire that destroyed GM’s transmission factory was the most destructive industrial fire in American history. Photo courtesy General Motors Corp. camilloj@bnpmedia.com (Jim Camillo) http://www.assemblymag.com/articles/94980 Wed, 08 May 2019 08:00:00 -0400 https://www.assemblymag.com/articles/94980-iiot-tech-on-assembly-lines 1 When connected to a smartphone app, the Bluetooth-enabled wristband Portable Quality Assurance Device helps assembly line workers make faster and more accurate quality checks on new vehicles. Photo courtesy Ford Motor Co. 2 Miniature O200 photoelectric sensors are designed to detect transparent, reflective and reflecting objects. Photo courtesy Baumer Ltd. 3 For several years, workers at AGCO Corp. have used Google Glass and the Glass Enterprise Edition to follow instructions so their hands are free to assemble tractors and crop applicators. Photo courtesy AGCO Corp. 4 The rugged xTablet T1680 mounts easily on assembly equipment and forklifts. It is durable enough to meet the MIL-STD 810G standard, which requires a device to be fully functional after a 4-foot drop. Photo courtesy MobileDemand L.C. 5 OEMs in various industries integrate the ex700 series of HMI-controllers in assembly machines to enhance their data gathering, storage and analysis capabilities. The devices can also be retrofit on older equipment to make them IIoT compatible. Photo courtesy Exor America Inc. 6 Workers at GE Healthcare’s factory in Hino, Japan, are equipped with smartwatches that help prevent assembly errors. Photo courtesy GE Healthcare 7 The DiVE HMI smartwatch can be tied to a factory’s manufacturing execution system to present data and alerts to assemblers and managers. Photo courtesy The Engineering Group http://www.assemblymag.com/articles/94999 Tue, 07 May 2019 09:00:00 -0400 https://www.assemblymag.com/articles/94999-configuration-management-how-to 1 Configuration management is what makes it possible to connect a set of requirements documents to a specific iteration of the product. Photo courtesy Matchtech Group Ltd. 2 Configuration management keeps track of the documentation that allows a company to produce the product. Photo courtesy Plymouth Industries 3 In product development, configuration management will set design attributes. Photo courtesy Fusion Career Services 4 Configuration management involves every department of a company, from marketing to aftermarket support. Photo courtesy CV Library Ltd. webera@bnpmedia.com (Austin Weber) http://www.assemblymag.com/articles/94979 Tue, 07 May 2019 08:00:00 -0400 https://www.assemblymag.com/articles/94979-the-reality-of-augmented-reality 1 Augmented reality brings components of the digital world into a person’s perception of the real world. Photo courtesy Upskill 2 Operators at AGCO use Glass eyewear and Proceedix work instruction software to improve assembly line productivity. Photo courtesy AGCO Corp. 3 As augmented reality technology has matured and become less expensive, more companies are using it in smart factories. Photo courtesy Upskill 4 Some manufacturers use augmented reality technology for material handling and bin picking applications. Photo courtesy Ubimax Inc. 5 Augmented reality is an important component of smart factories. Photo courtesy Avanade 6 The HMT-1 is a popular device used for augmented reality applications. Photo courtesy RealWear Inc. 7 Boeing uses augmented reality for wiring harness assembly applications. Photo courtesy Upskill 8 Smart glasses are lightweight devices popular for assisted reality and informed reality applications. Photo courtesy Ubimax Inc. 9 Augmented reality provides a see-through visual capability mixed with graphic overlays that appear to be suspended in the surrounding real-world environment. Photo courtesy Upskill 10 With mixed reality technology, engineers can immerse themselves in product designs. Photo courtesy Fraunhofer 11 Microsoft’s HoloLens device helps automotive engineers design assembly lines. Photo courtesy Ford Motor Co.