Manufacturing Assembly Handbook

PrefaceForeword1. Introduction 1.1 Assembly 1.2 Status of Assembly in the Production Operation2. Product Design as a Requirement for Economic Assembly 2.1 Product Design 2.1.1 Base Part 2.1.2 Number of Parts 2.2 Assembly-Extended ABC Analysis 2.2.1 Fundamental Question 1: Price of Individual Parts and their Manufacturing Costs 2.2.2 Fundamental Question 2: Supply Condition 2.2.3 Fundamental Question 3: Ease of Handling 2.2.4 Fundamental Question 4: Assembly Direction and Ease of Assembly 2.2.5 Fundamental Question 5: Assembly Methods 2.2.6 Fundamental Question 6: Quality 2.2.7 Fundamental Question 7: Assembly Costs 2.2.8 Organizational Implementation of the Assembly-Extended ABC Analysis3. Manual Assembly 3.1 Introduction 3.2 Principles of Work-Point Arrangement 3.3 Organizational Forms of Manual Assembly 3.3.1 Single-Point Assembly 3.3.2 Line Assembly4. Primary-Secondary Analysis - An Aid for the Determination of the Economic Efficiency of Assembly Concepts 4.1 Introduction 4.2 Definition of the Efficiency of Assembly Operations 4.3 Field of Application 4.3.1 Basic Analysis 4.3.2 Fine Analysis of Single Assembly Work Points in Terms of Primary and Secondary Processes 4.4 Application Example of Assembly Analysis by Primary and Secondary Activity 4.4.1 Single Assembly Work Point with Provision of Parts in Manual Parts Dispensers 4.4.2 Single Assembly Work Point with Parts Provision by a Parts Paternoster 4.4.3 Single Assembly Work Point, Parts Provision Partly by Manual Parts Dispensers and Partly by Vibratory Spiral Conveyors 4.4.4 Linking of Three Single Assembly Work Points to Form a Line Assembly with Manual Transfer of the Assembled Part 4.4.5 Linking of Three Single Assembly Work Points to Form a Line Assembly with Mechanical Transfer of the Assembled Part in Workpiece Carriers 4.4.6 Summary and Efficiency Consideration 4.4.7 Primary-Secondary Fine Analysis for the Handling and Assembly of a Single Part 4.5 Extended Analysis in Terms of Primary and Secondary Requirements for the Total Sequence of an Assembly Operation 4.6 Practical Examples 4.6.1 Example 1: Switch Assembly 4.6.2 Example 2: Switch Element 4.6.3 Example 3: Headlight Assembly5. Modules for the Automation of Assembly Processes 5.1 Introduction 5.1.1 Handling 5.2 Feeder Units 5.2.1 Feeder Units for Parts with One Arrangement Feature 5.2.2 Feeder Units for Parts with Several Arrangement Criteria 5.2.3 Electronic Position Identification of Parts 5.2.4 The Feed of Interlocking Parts 5.3 Handling Equipment 5.3.1 Positioning Units 5.3.2 Industrial Robots 5.4 Transfer Equipment 5.4.1 Cycled Transfer Equipment 5.4.2 Non-Cycled Transfer Equipment 5.5 Screw-Inserting Units 5.6 Riveting Units 5.6.1 Press-Riveting 5.6.2 Rotating-Mandrel Riveting 5.7 Welding Units 5.7.1 Resistance Welding 5.7.2 Laser Welding Equipment 5.8 Soldering Equipment 5.9 Bonding6. Design of Assembly Machines 6.1 Introduction 6.2 Single-Station Assembly Machines 6.3 Multi-Station Assembly Machines 6.3.1 Design of Parts Feed Stations 6.3.2 Checking Stations 6.3.3 Design of Pneumatically Operated Multi-Station Assembly Machines 6.3.4 Design of Electric-Motor Driven Multi-Station Assembly Machines 6.3.5 Assembly Machine Systems 6.4 Combining Assembly Machines to Form Assembly Lines 6.5 Integration of Manual Work Points in Automated Assembly Lines 6.5.1 Manual Work Points for Parts Provision 6.5.2 Manual Assembly Work Points 6.6 Uncycled Assembly Lines Including Manual Work Points 6.