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Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes.  Correctly applied, DFM+A analysis leads to significant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes.  This course will include information on how DFM+A fits in with QFD, Concurrent Engineering, Robust Engineering, and other disciplines.

This course is verified by Probitas Authentication as meeting the AS9104/3A requirements for continuing Professional Development. Why is a design for manufacturing, assembly and automation so important? This introductory course on airframe engineering will cover the importance of design for manufacturing, assembly and automation in aerospace. It will review what the key drivers are for a “good” design and some of the key points for manufacturing and assembly of aircraft components. It will look at how an engineer can combine traditional technologies with new, cutting-edge technologies, to determine the best scenario for success.

This course examines ADAS and autonomous vehicle technologies that offer the potential to increase safety while attempting to optimize the cost of car ownership. LIDAR (light detection ranging) and Infrared camera sensing are seeing a rapid growth and adoption in the industry. However, the sensor requirements and system architecture options continue to evolve almost every six months. This course will provide the foundation to build on for these two technologies in automotive applications. It will include a demonstration model for LIDAR and Infrared camera.

Advanced Driver Assist System (ADAS) and autonomous vehicle technologies have disrupted the traditional automotive industry with potential to increase safety and optimize the cost of car ownership. Light detection and ranging (LIDAR) sensing, a sensing method that detects objects and maps their distances, is seeing rapid growth and adoption in the industry. However, the sensor requirements and system architecture options continue to evolve. This course will provide the foundation to build LIDAR technologies in automotive applications.

Advanced Driver Assist System (ADAS) and autonomous vehicle technologies have disrupted the traditional automotive industry with potential to increase safety and optimize the cost of car ownership. Among the challenges are those of sensing the environment in and around the vehicle. Infrared camera sensing is seeing a rapid growth and adoption in the industry. The applications and illumination architecture options continue to evolve. This course will provide the foundation on which to build near infrared camera technologies for automotive applications.

Photographs and video recordings of vehicle crashes and accident sites are more prevalent than ever, with dash mounted cameras, surveillance footage, and personal cell phones now ubiquitous. The information contained in these pictures and videos provide critical information to understanding how crashes occurred, and  analyze physical evidence. This course teaches the theory and techniques for getting the most out of digital media, including correctly processing raw video and photographs, correcting for lens distortion, and using photogrammetric techniques to convert the information in digital media to usable scaled three-dimensional data.

Convolutional neural networks are the de facto method of processing camera, radar, and lidar data for use in perception in ADAS and L4 vehicles, yet their operation is a black box to many engineers. Unlike traditional rules-based approaches to coding intelligent systems, networks are trained and the internal structure created during the training process is too complex to be understood by humans, yet in operation networks are able to classify objects of interest at error rates better than rates achieved by humans viewing the same input data.

Many technical projects, most vehicle and component testing, and all accident reconstructions, product failure analyses, and other forensic investigations, require photographic documentation. Roadway evidence disappears, tested or wrecked vehicles are repaired, disassembled, or scrapped, and components can be tested for failure. Photographs are frequently the only evidence that remains of a wreck, or the only records of subjects before or during tests. Making consistently good images during any inspection is a critical part of the evaluation process. 

Design for Manufacturing and Assembly (DFM+A), pioneered by Boothroyd and Dewhurst, has been used by many companies around the world to develop creative product designs that use optimal manufacturing and assembly processes. Correctly applied, DFM+A analysis leads to significant reductions in production cost, without compromising product time-to-market goals, functionality, quality, serviceability, or other attributes. In this two-day course, you will not only learn the Boothroyd Dewhurst Method, you will actually apply it to your own product design!

This specification covers all-metal, self-locking nuts, plate nuts, and gang channel nuts made of a carbon or low-alloy steel.

This specification covers all-metal, self-locking, prevailing-torque nuts, plate nuts, and gang channel nuts made of a carbon or low-alloy steel.

Optical fiber has begun replacing copper in avionic networks. So far, however, it has been mainly restricted to non-critical applications (video transmission to the flight deck, IFE?). In order to take advantage of the high-bandwidth, low weight, no EMI properties of optical fibers in all data transmission networks, it will be necessary to improve the testing. One part of the puzzle, which is still missing, is the self-test button: the possibility to check the network and detect potential failures before they occur. The typical testing tool of a technician involved in optical fiber cables is the ?light source ? optical power meter? pair. With this tool, one can measure the insertion loss of the fiber link. A second important parameter, the return loss at each optical connector, is not analysed. In addition, this is only a global measurement, which does not allow the detection of possible weak points.

This article characterizes the special features of drilling of CFRP/Titanium and -Aluminium stacks. Simplified theoretic models will show how CFRP/Titanium stacks should be machined without scratches and burn marks contacting carbon. Low axial forces and smart chip removal technology are the main characteristics of the drilling tool technology, optimized to reach H8 quality in one shot operation. Presenter Peter Mueller-Hummel, Cutting Tools Inc.

“Spotlight on Design” features video interviews and case studies, focusing on technology breakthroughs, hands-on testimonials, and the importance of fundamentals. Viewers are virtually taken to industry labs and research centers to learn how design engineers solve real-life problems. These challenges include enhancing product performance, reducing costs, improving quality and safety, while decreasing environmental impact, and achieving regulatory compliance. In the episode “Additive Manufacturing: 3D Printing in the Automotive Industry” (20:00), engineers from Fiat Chrysler Corporation (FCA) explain the importance of using 3D printing to test multiple design scenarios and develop solutions that can be quickly evaluated on test tracks. And Local Motors shows how it builds a vehicle from the ground up with a 3D printer, and without a traditional assembly line.

In Aeronautic industry, when we launch a new industrialization for an aircraft sub assembly we always have the same questions in mind for drilling operations, especially when focusing on lean manufacturing. How can we avoid dismantling and deburring parts after drilling operation? Can a drilling centre perform all the tasks needed to deliver a hole ready to install final fastener? How can we decrease down-time of the drilling centre? Can a drilling centre be integrated in a pulse assembly line? How can we improve environmental efficiency of a drilling centre? It is based on these main drivers that AIRBUS has developed, with SPIE and SOS, a new generation of drilling centre dedicated for hard materials such as titanium, and high thicknesses. The first application was for the assembly of the primary structure of A350 engine pylons. The main solution that was implemented meeting several objectives was the development of orbital drilling technology in hard metal stacks.

The foundation of many production aircraft assembly facilities is a more dynamic and unpredictable quantity than we would sometimes care to admit. Any tooling structures constructed on these floors, no matter how thoroughly analyzed or well understood, are at the mercy of settling and shifting concrete, which can cause very lengthy and costly periodic re-certification and adjustment procedures. It is with this in mind, then, that we explore the design possibilities for one such structure to be built in Belfast, North Ireland for the assembly of the Shorts C-Series aircraft wings. We evaluate the peak floor pressure, weight, gravity deflection, drilling deflection, and thermal deflection of four promising structures and discover that carefully designed pivot points and tension members can offer significant benefits in some areas.

A significant step is achieved on the flight control actuation system toward the more electrical aircraft through the Airbus A380, A400M and the A350 development phase ongoing. The A380/A400M/A350 features a mixed flight control actuation power source distribution, associating electrically powered actuators with conventional FlyByWire hydraulic servocontrols. In the scope of the preparation of the future Airbus Aircraft, this paper presents the perspectives of the use of the EMA technologies for the flight control systems in the more electrical aircraft highlighting the main technical challenges need to treat: jamming susceptibility, ?on board? maintenance reduction, Operational reliability increase, power electronics and power management optimization, and regarding the environmental constraints, the predicted performances; the benefits associated to the optimized utilization of on-board power sources.

Using pressure sensitive adhesive tapes to achieve economy and efficiency in automotive assembly