Chapter 1 Introduction |
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1 | (16) |
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1.1 Historical Development of the Assembly Process |
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2 | (4) |
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1.2 Choice of Assembly Method |
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6 | (4) |
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1.3 Social Effects of Automation |
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10 | (5) |
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15 | (2) |
Chapter 2 Automatic Assembly Transfer Systems |
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17 | (12) |
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17 | (1) |
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2.2 Intermittent Transfer |
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17 | (6) |
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23 | (4) |
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2.4 Operator-Paced Free-Transfer Machine |
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27 | (1) |
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28 | (1) |
Chapter 3 Automatic Feeding and Orienting - Vibratory Feeders |
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29 | (62) |
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3.1 Mechanics of Vibratory Conveying |
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29 | (5) |
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34 | (1) |
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3.3 Effect of Track Acceleration |
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34 | (1) |
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3.4 Effect of Vibration Angle |
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35 | (1) |
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3.5 Effect of Track Angle |
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35 | (2) |
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3.6 Effect of Coefficient of Friction |
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37 | (1) |
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3.7 Estimating the Mean Conveying Velocity |
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38 | (4) |
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42 | (2) |
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3.9 Solutions to Load Sensitivity |
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44 | (2) |
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46 | (1) |
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47 | (1) |
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3.12 Orientation of Parts |
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47 | (1) |
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3.13 Typical Orienting System |
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48 | (6) |
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3.14 Effect of Active Orienting Devices on Feed Rate |
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54 | (1) |
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3.15 Analysis of Orienting Systems |
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55 | (8) |
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57 | (1) |
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3.15.2 Method of System Analysis |
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58 | (3) |
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61 | (2) |
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3.16 Performance of an Orienting Device |
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63 | (6) |
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63 | (6) |
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3.17 Natural Resting Aspects of Parts for Automatic Handling |
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69 | (9) |
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70 | (1) |
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3.17.2 Analysis for Soft Surfaces |
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71 | (6) |
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3.17.3 Analysis for Hard Surfaces |
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77 | (1) |
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3.17.4 Analysis for Cylinders and Prisms with Displaced Centers of Mass |
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78 | (1) |
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3.17.5 Summary of Results |
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78 | (1) |
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3.18 Analysis of a Typical Orienting System |
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78 | (9) |
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3.18.1 Design of Orienting Devices |
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85 | (2) |
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87 | (2) |
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89 | (2) |
Chapter 4 Automatic Feeding and Orienting - Mechanical Feeders |
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91 | (40) |
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4.1 Reciprocating-Tube Hopper Feeder |
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92 | (2) |
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94 | (1) |
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4.1.2 Specific Applications |
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94 | (1) |
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4.2 Centerboard Hopper Feeder |
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94 | (6) |
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4.2.1 Maximum Track Inclination |
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94 | (5) |
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4.2.2 Load Sensitivity and Efficiency |
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99 | (1) |
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4.3 Reciprocating-Fork Hopper Feeder |
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100 | (2) |
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4.4 External Gate Hopper Feeder |
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102 | (6) |
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102 | (4) |
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4.4.2 Load Sensitivity and Efficiency |
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106 | (2) |
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108 | (2) |
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4.5.1 Indexing Rotary-Disk Feeder |
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108 | (1) |
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4.5.2 Rotary-Disk Feeder with Continuous Drive |
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109 | (1) |
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4.5.3 Load Sensitivity and Efficiency |
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110 | (1) |
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4.6 Centrifugal Hopper Feeder |
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110 | (5) |
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111 | (3) |
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114 | (1) |
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4.7 Stationary-Hook Hopper Feeder |
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115 | (4) |
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115 | (3) |
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118 | (1) |
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4.8 Bladed-Wheel Hopper Feeder |
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119 | (1) |
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4.9 Tumbling-Barrel Hopper Feeder |
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119 | (5) |
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121 | (3) |
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4.10 Rotary-Centerboard Hopper Feeder |
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124 | (1) |
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4.11 Magnetic-Disk Feeder |
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124 | (1) |
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4.12 Elevating Hopper Feeder |
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125 | (1) |
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4.13 Magnetic Elevating Hopper Feeder |
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126 | (1) |
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126 | (4) |
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130 | (1) |
Chapter 5 Feed Tracks, Escapements, Parts-Placement Mechanisms, and Robots |
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131 | (56) |
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131 | (27) |
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5.1.1 Analysis of Horizontal-Delivery Feed Track |
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132 | (5) |
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137 | (2) |
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139 | (4) |
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140 | (3) |
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143 | (3) |
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5.1.5 Design of Gravity Feed Tracks for Headed Parts |
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146 | (12) |
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146 | (7) |
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153 | (5) |
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5.1.5.3 Procedure for Use of Figure 5.17 to Figure 5.20 |
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158 | (1) |
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158 | (3) |
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160 | (1) |
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161 | (7) |
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5.3.1 Ratchet Escapements |
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162 | (2) |
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164 | (1) |
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165 | (2) |
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167 | (1) |
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167 | (1) |
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5.4 Parts-Placing Mechanisms |
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168 | (3) |
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171 | (15) |
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171 | (1) |
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5.5.2 Advantages of Robot Assembly |
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172 | (2) |
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174 | (1) |
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5.5.4 Types of Magazine Systems |
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175 | (1) |
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5.5.5 Automatic Feeders for Robot Assembly |
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175 | (3) |
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5.5.6 Economics of Part Presentation |
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178 | (4) |
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5.5.7 Design of Robot Assembly Systems |
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182 | (4) |
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186 | (1) |
Chapter 6 Performance and Economics of Assembly Systems |
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187 | (32) |
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187 | (8) |
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6.1.1 Effect of Parts Quality on Downtime |
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187 | (1) |
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6.1.2 Effects of Parts Quality on Production Time |
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188 | (2) |
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6.1.3 Effect of Parts Quality on the Cost of Assembly |
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190 | (5) |
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6.2 Free-Transfer Machines |
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195 | (6) |
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6.2.1 Performance of a Free-Transfer Machine |
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196 | (4) |
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6.2.2 Average Production Time for a Free-Transfer Machine |
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200 | (1) |
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6.2.3 Number of Personnel Needed for Fault Correction |
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200 | (1) |
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6.3 Basis for Economic Comparisons of Automation Equipment |
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201 | (3) |
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6.3.1 Basic Cost Equations |
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202 | (2) |
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6.4 Comparison of Indexing and Free-Transfer Machines |
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204 | (3) |
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204 | (1) |
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6.4.2 Free-Transfer Machine |
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205 | (1) |
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6.4.3 Effect of Production Volume |
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205 | (2) |
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6.5 Economics of Robot Assembly |
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207 | (10) |
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208 | (3) |
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6.5.2 Profile of Typical Candidate Assembly |
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211 | (1) |
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6.5.3 Single-Station Systems |
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212 | (3) |
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212 | (1) |
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213 | (1) |
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213 | (1) |
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6.5.3.4 Basic Cost Equation |
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214 | (1) |
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6.5.4 Multistation Transfer Systems |
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215 | (6) |
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215 | (1) |
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216 | (1) |
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217 | (2) |
Chapter 7 Design for Manual Assembly |
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219 | (38) |
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219 | (1) |
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7.2 Where Design for Assembly Fits in the Design Process |
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219 | (2) |
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7.3 General Design Guidelines for Manual Assembly |
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221 | (6) |
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7.3.1 Design Guidelines for Part Handling |
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221 | (1) |
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7.3.2 Design Guidelines for Insertion and Fastening |
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222 | (5) |
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7.4 Development of a Systematic DFA Analysis Method |
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227 | (2) |
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229 | (1) |
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7.6 Classification System for Manual Handling |
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230 | (3) |
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7.7 Classification System for Manual Insertion and Fastening |
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233 | (3) |
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7.8 Effect of Part Symmetry on Handling Time |
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236 | (1) |
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7.9 Effect of Part Thickness and Size on Handling Time |
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237 | (2) |
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7.10 Effect of Weight on Handling Time |
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239 | (1) |
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7.11 Parts Requiring Two Hands for Manipulation |
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240 | (1) |
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7.12 Effects of Combinations of Factors |
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240 | (1) |
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240 | (2) |
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7.14 Effects of Holding Down |
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242 | (1) |
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7.15 Problems with Manual Assembly Time Standards |
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242 | (2) |
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7.16 Application of the DFA Method |
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244 | (7) |
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7.16.1 Results of the Analysis |
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248 | (3) |
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7.17 Further General Design Guidelines |
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251 | (3) |
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254 | (3) |
Chapter 8 Product Design for High-Speed Automatic Assembly and Robot Assembly |
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257 | (34) |
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257 | (1) |
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8.2 Design of Parts for High-Speed Feeding and Orienting |
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258 | (5) |
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263 | (2) |
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8.4 Additional Feeding Difficulties |
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265 | (1) |
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8.5 High-Speed Automatic Insertion |
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266 | (3) |
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269 | (2) |
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8.7 Analysis of an Assembly |
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271 | (1) |
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8.8 General Rules for Product Design for Automation |
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272 | (4) |
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8.9 Design of Parts for Feeding and Orienting |
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276 | (4) |
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8.10 Summary of Design Rules for High-Speed Automatic Assembly |
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280 | (1) |
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8.10.1 Rules for Product Design |
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280 | (1) |
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8.10.2 Rules for the Design of Parts |
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280 | (1) |
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8.11 Product Design for Robot Assembly |
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281 | (8) |
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8.11.1 Summary of Design Rules for Robot Assembly |
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287 | (2) |
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289 | (2) |
Chapter 9 Printed-Circuit-Board Assembly |
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291 | (20) |
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291 | (1) |
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291 | (1) |
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9.3 Assembly Process for PCBs |
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292 | (9) |
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301 | (1) |
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9.5 Estimation of PCB Assembly Costs |
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302 | (1) |
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9.6 Worksheet and Database for PCB Assembly Cost Analysis |
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303 | (2) |
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303 | (2) |
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9.7 PCB Assembly - Equations and Data for Total Operation Cost |
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305 | (3) |
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306 | (1) |
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9.7.2 Autoinsertion Machine |
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306 | (1) |
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9.7.3 Robot Insertion Machine |
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306 | (2) |
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308 | (2) |
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310 | (1) |
Chapter 10 Feasibility Study for Assembly Automation |
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311 | (52) |
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10.1 Machine Design Factors to Reduce Machine Downtime Due to Defective Parts |
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312 | (1) |
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313 | (19) |
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10.2.1 Precedence Diagrams |
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314 | (3) |
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10.2.2 Manual Assembly of Plug |
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317 | (1) |
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10.2.3 Quality Levels of Parts |
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318 | (1) |
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10.2.4 Parts Feeding and Assembly |
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319 | (2) |
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10.2.5 Special-Purpose Machine Layout and Performance |
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321 | (5) |
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10.2.5.1 Indexing Machine |
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321 | (3) |
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10.2.5.2 Free-Transfer Machine |
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324 | (2) |
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10.2.6 Robot Assembly of the Power Plug |
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326 | (6) |
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332 | (1) |
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333 | (30) |
Appendix A Simple Method for the Determination of the Coefficient of Dynamic Friction |
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363 | (6) |
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363 | (2) |
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365 | (1) |
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A.3 Precision of the Method |
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366 | (1) |
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366 | (2) |
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368 | (1) |
Appendix B Out-of-Phase Vibratory Conveyors |
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369 | (6) |
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B.1 Out-of-Phase Conveying |
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370 | (2) |
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B.2 Practical Applications |
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372 | (1) |
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373 | (2) |
Appendix C Laboratory Experiments |
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375 | (10) |
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C.1 Performance of a Vibratory-Bowl Feeder |
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375 | (4) |
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375 | (1) |
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375 | (1) |
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375 | (1) |
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376 | (2) |
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C.1.5 Presentation of Results |
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378 | (1) |
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C.2 Performance of a Horizontal-Delivery Gravity Feed Track |
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379 | (6) |
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379 | (1) |
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C.2.2 Equipment (Objective 1) |
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379 | (1) |
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C.2.3 Theory (Objective 1) |
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380 | (1) |
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C.2.4 Procedure (Objective 1) |
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381 | (1) |
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C.2.5 Results (Objective 1) |
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381 | (1) |
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C.2.6 Equipment (Objective 2) |
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381 | (1) |
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C.2.7 Theory (Objective 2) |
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382 | (1) |
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C.2.8 Procedure (Objective 2) |
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382 | (1) |
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C.2.9 Results (Objective 2) |
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383 | (1) |
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383 | (2) |
Appendix D Feeding and Orienting Techniques for Small Parts |
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385 | (116) |
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385 | (23) |
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D.1.1 Introduction to the Coding System |
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386 | (4) |
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390 | (2) |
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D.1.3 Sample Parts for Practice |
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392 | (1) |
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D.1.4 Analysis of the Coding of the Sample Parts |
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393 | (2) |
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D.1.5 Coding System for Small Parts |
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395 | (13) |
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D.2 Feeding and Orienting Techniques |
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408 | (66) |
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D.3 Orienting Devices for Vibratory-Bowl Feeders |
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474 | (18) |
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492 | (9) |
Nomenclature |
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501 | (6) |
Index |
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507 | |