Automation – Page 195
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ArticleCT scrutiny
In aiming for quality targets, castings supplier Grainger & Worrall regards this technology as a game-changerThe time has long gone when automotive suppliers – certainly those at tier-one level – did nothing but supply parts to order. Now they must also frequently act as partners in component design and ...
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Article
CT检测
供应商们将目标定在质量与可靠性标准上，AMS与一家将计算机断层摄影作为秘诀的铸造公司交流探讨。汽车供应商（就是那些一级供应商）只需按照提供零部件的时代一去不复返了。现在，他们还要扮演组件设计与开发伙伴的职责，在保证及时的同时，还要保证质量。英国铸件供应商Grainger&Worrall公司总监Edward Grainger对当今业内生存方法进行了精炼概述。该公司为私有企业，拥有600名员工，主要进行铸件的开发和生产，应用于发动机、变速器和结构应用上。Grainger承认说，公司的企业文化可能有点“保守”，但是在技术的使用态度上却非如此。这体现在从设计到制造商的各个方面。比如，公司不仅拥有3个CAD系统内 — Dassault Systemes，PTC和Siemens — 而且还有超声波、射线、计算机断层摄影硬件（CT）。Grainger称，每个技术与医用具有直接关系，而且还是先进的工业设备。事实上，在过去的10年里，CT一直是Grainger & Worrall公司的铁一般的事实。之所以被引进是因为公司发现超声波和射线综合技术已经无法满足公司对质量控制和产品可靠性方面的目标。Grainger解释说，铸件上微乎其微的缺陷都可能产生极具危害的后果。公司发现一个能够更加朱雀发现缺陷的方法，因此就放弃原来的相关技术。他直截了当地说，“这是我们没有估计到的风险。”更多毁坏性试验 Part of the process is a painstaking slice-by-slice visual inspection of CT data在更实用层面上，这个技术已经能让公司极大减少对昂贵铸件进行破坏性测试的必要。Grainger称，该技术有效消除对零部件进行瑕疵测试和尺寸精确度而进行的破坏性。现在，唯一需要进行破坏性试验的就是“为了进行机械性能测试，比如确定特殊区域的张力或剩余应力，而不得不进入到零部件内部。”他说，预计CT在每个原型项目中需要切碎两个至三个逐渐，因此每年需要毁掉两千个完好无损的零部件铸件。此外，正如Grainger解释的，如果受损，就无法出售造价高昂的铸件，造成无谓的浪费，因此“切碎零部件”并不是质量监控的可靠方法。如果当前的目标是保证生产流程，按照规格生产零部件，那么替代方案就会受到质疑。正如他说的：“我们什么时候能停止切碎零部件，然后开始新的流程？”Grainger说，CT为公司带来的根本生产力是就是能够从3个维度准确查出逐渐内部的缺陷，甚至是一个气泡或沙粒。他还说，X涉嫌可能检测这样的缺陷，但是无法确定确切的位置，因为所有铸件都是同事检测的。他说，“事情没有绝对的”，并接着说，他们的说明需要有经验的人拿出非常客观的证据。相反，CT能够在一系列“切片”中检查到一个物体，不仅能检测出瑕疵的尺寸和特性，还能查到具体位置。虽然还是需要技术说明，但是结果客观得多。而且这种可观性还以另一种形式诠释 — 即精确测量。Grainger解释说，“这能精确测量一个零部件。”这种特质能使受测零部件在制造过程中从液态转化成固态。CT是检测手段的必要部分据Grainger&Worrall公司称，初期投资了350,000英镑引进了第一台机器，3年之后又投资了这些钱，机器也是一样的。在过去的10年里，估计已经向该技术投资了大约750,000英镑。在利用方面就更加恰当、更加强化。两台机器24小时运转，在进行质量控制的同时还当作开发支持工具。Grainger称，对前者来说，之前客户要求少批量可靠的发动机（比如第一方程式团队），而是用CT作为100%的审查技术完全不需要“动脑”。这是成本效益极高的技术，势如破竹，按照合同要求是用机器。而对后者来说，机器的使用更加特别。他说，开发工程师们经常拿一个零部件到其中一个CT机器上，看看在进行细节检查时是否存在时隙，有的瑕疵可能用X射线或传统的坐标测量的方法测出会产生严重后果。因此，很显然，公司将CT当做综合审查和分析技术的一部分，而不是孤立程序。一个集中化CT分析程序会通常用于检查几百“片”中的一个零部件，每个厚度为1mm，范围在0.75-2.00mm之间。Grainger称，在这个过程中，每片可能需要一分钟的时间，因此一个300mm后的工件大约需要CT机器工作5个小时。但是，这种情况通常会在无人值班的夜里进行。这个流程的产物包括两个因素。第一个是“断层摄影报告”，能够精确识别任何在0.2mm宽度瑕疵的性质。第二个是精确的3D展示图，呈现零部件的内外集合结构，并与相关3D CAD参考数据相比较，保证制造出来的零部件与设计意图一致。尤其重要的是，发动机铸件的内部沟道如果不用一个内部非会话性方法是检测不到的。此外，这种性能不仅能够检测铸件内部流程的一致性，而且还能保证之后的加工不会抵消产品的质量。比如说，钻孔的准确位置可以稍微“扭曲”，就能保证不会恶化，否则就会被认定为轻微的瑕疵。这种流程的结果可以当做公司和客户在互动的基础上进行远程交流。Grainger说，客户可以远程注册公司内部网络，或者可以将兴趣领域资料发过去。事实上，Grainger认为，这种互动变得越来越容易，归功于台式电脑的不断发展，而广域网一斤更成为这是技术从安装之初到后面的使用推广中不可忽视的关键。人为检查“切片”真正的机器 — 两台XYLON CT压缩机器 — 并列放在厂区主楼一间大屋里。这些机器受到计量部经理Gary Breech的管理，他说这些机器能够负责最大尺寸为直径500mm，高度750mm的工件。在实际应用上，机器的能力只应付过这种尺寸的铝质工件。铁质零部件的最大宽度为100mm。他还肯定地说，在将这些工件人工搬到桌面里面之后，每个机器和门都会关掉，然后进入自动化程序。 The software system Volume Graphics transforms the initially “flat” slices generated by the CT system into much richer 3D ...
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ArticleChlorine free cutting oil
Condat says it has developed a high performance, chlorine free cutting oil in response to pending regulations regarding the use of chlorinated paraffins in metalworking fluids.The company says its Condacut DP 415 formulation uses EP additives with an inactive sulphur-based chemistry and it has been specifically designed for high performance, ...
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ArticleAcura PMC set to make new NSX
US – Series production of the next-generation supercar will begin in late April at the new Performance Manufacturing Center (PMC) in Marysville, Ohio. The twin-turbocharged V6 engines will be made at the nearby factory in Anna by a small team of specialists. NSX trial production is already underway.The PMC will ...
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ArticleSwarf management system
Yamazaki Mazak says it will now offer a swarf management system as part of its ‘Performance Package’ of machine peripherals for machining centres in its VCS range of vertical machine tools.The Turbo MH series (supplied by LNS Europe) has a built-in scraper bar attached to the hinge belt that continuously ...
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ArticleCalsonic shares best practices with R-TEK
UK – A team from the interior trim supplier visited Calsonic Kansei in Sunderland, as part of the North-East Automotive Alliance (NEAA) Business Excellence programme. The knowledge gained has led to improved training at R-TEK.The trim supplier underwent a ‘World-Class Quality Performance’ visit to Calsonic, plus follow-up meetings, and subsequently ...
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ArticleBMW releases Sustainable Value Report
Germany – The document provides an update on the OEM’s sustainability strategy, targets and progress in 2015. BMW stated that it is “firmly committed” to the United Nations Global Compact, having implemented its ten principles since 2001.“We have set ourselves concrete sustainability targets we aim to meet by 2020,” said ...
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ArticleITT to open brake plant at Silao
Mexico – The factory in Guanajuato state will begin off-tool and off-process brake pad manufacture in late 2017, with series production scheduled for the first quarter of 2018. ITT says the plant will feature “state-of-the-art” technology in keeping with its global standards, including material science expertise and high product consistency.“Our ...
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ArticleNew GM at Dacia and Renault Romania
Romania – Yves Caracatzanis will replace Nicolas Maure as general manager, when the latter takes up the leadership of AvtoVAZ on April 4. Caracatzanis will report to Denis Le Vot, senior vice-president (SVP) and director of operations for Eurasia.Caracatzanis began his career with Bossard Consultants, then moved to Hewlett Packard ...
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ArticleDaimler Mannheim’s century of training
Germany – The first 30 recruits arrived at the plant in 1916, since when almost 11,000 young people have received vocational training onsite. Daimler says there are currently 380 trainees in nine disciplines and on three dual-study courses.Describing robust vocational training as “the basis for our corporate success”, Marcus Nicolai, ...
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ArticleMaure to lead AvtoVAZ
Russia – Nicolas Maure will take up the role of CEO which will be vacated by Bo Andersson on April 4. Maure is currently managing director of Renault Group in Romania, as well as president and CEO of Automobile Dacia.“AvtoVAZ has modernised its line-up and manufacturing processes, and significantly improved ...
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ArticleThe case for carbon fibre
The composites industry’s flagship event, JEC World, was bigger than ever this year. The number of exhibitors showing off their automotive expertise at this month’s show and conference in Paris was particularly striking. The use of glass-fibre-reinforced composites is established for the production of non-structural internal and external parts for ...
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ArticleAdams to lead Lectra in North America
US – As president of the region, Jason Adams will develop the company’s presence in the US, Canada, Mexico and Central American markets, in automotive and the other industries it serves. He will be based in Atlanta, Georgia, and report to Lectra CEO Daniel Harari.Before joining Lectra, Adams served manufacturing ...
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ArticleToyota RAV4 allocated to St Petersburg
Russia – The model will be produced alongside the Camry from August this year, for sale in Russia, Belarus and Kazakhstan. Toyota has invested 7.1 billion roubles ($100.7m) in the plant to expand the production areas, install new equipment and increase automation in the press shop, bodyshop and assembly hall. ...
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WebinarNIKON Webinar: Laser Radar: next-generation CMM for shop floor car body inspection
Wednesday 13 April 15:00 BST | 16:00 CET | 10:00 EDTInnovative inspection stations are being installed today, both lineside and offline, by major automotive OEMs using Nikon Metrology’s Laser Radar.In this webinar, we look at how the non-contact, automated Laser Radar is providing OEMs with an effective alternative to the ...
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ArticleAudi develops lightweight tooling
Germany – The company’s tooling specialists have developed a new generation of tools that they say are up to 20% lighter and 10% more stable than the previous generation. Now being used in the press shop at Ingolstadt, the new tools feature a composite construction consisting of cast iron, aluminium ...
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ArticleIPS milestone at Mercedes-Benz Kassel
Germany – The plant has now produced 100,000 truck axles using induction pressure welding (IPS in abbreviated German). The technology enables the joining of steel and cast parts with any contours, says parent company Daimler, claiming it is “unique in the world”.In IPS, the main body or housing of the ...
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ArticleElio to sell 100 pre-production units
US – The company says the sale will enable the evaluation of its vehicles under real-world conditions and design refinement by the supplier team, as well as bringing in additional revenue. The first 100 units were previously intended for internal use.‘The work we do on these vehicles will provide important ...
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Article
VW's new VP for product innovations
US – In his role as vice-president at Volkswagen’s North American Engineering and Planning Center (EPC), Burkhard Huhnke will encourage innovation in the market, build relationships with national R&D organisations and liaise with universities. His appointment is effective immediately.“Dr Burkhard Huhnke’s 18 years of experience in research and development have ...
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ArticleFreels to head up HATCI
US – As president of Hyundai America Technical Center (HATCI), William Freels will be responsible for leading engineering groups that will develop global platforms for both North and South American markets. Educated in Texas and already based in Michigan, Freels becomes the first local executive to assume the HATCI presidency.Freels ...