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Pneumatic, manually operated, drilling machines are used to produce a significant proportion of all holes drilled during wing manufacture. Drilling machine design and the manual drilling process has not changed significantly in decades. By employing miniature, low power, electronics and interfacing techniques, a monitoring system has been developed. This system enables improved process control of the manual drilling operation. Machine calibration management, measurement of drill performance, jig drilling error control and asset management are some of the benefits attainable. This project will hopefully encourage others to discover the potential for improving historically established processes, by employing modern technological developments.

The onboard “SODART” telescope silicon detector cooling system of the “Spectrum-X-Gamma” observatory, which is designed for the space objects X-ray radiation study, is described. The scale-down model of the passive cooling system description and thermal vacuum test results of this model are given. In the real cooling system the minimal detector temperature at 300 mW heat release is expected about 107 K.

Nisshin Steel Co., Ltd. has developed a new process for the production of a “one-side aluminized steel sheet”. The process utilizes a double layer one-side “stop-off” coating to prevent the molten Al from adhering to the steel surface. The “Stop-off” coating is removed by simple mechanical brushing after hot dipping. The characteristics of this product by above mentioned process are: 1) The steel side was as clean as a conventional cold rolled surface and showed no trace of the “stop-off” layer. Thereby, phosphating and ED painting were performed. 2) In the salt spray test data was obtained from zinc and Al coated steel surfaces; the coatings on both surfaces being of equal thickness.

Engineers doing squeak and rattle testing of instrument panels (IP's) have successfully used large electrodynamic vibration systems to identify sources of squeaks and rattles (S&R's). Their successes led to demands to test more IP's, i.e., to increase throughput of IP's to reflect the many design, material, and/or manufacturing process changes that occur, and to do so at any stage of the development, production, or QA process. What is needed is a radically different and portable way to find S&R's in a fraction of the time and at lower capital cost without compromising S&R detection results.

Mathematical modeling and control of artificial ecosystems, such as MELISSA, require first the study of physical and biological characteristics in optimal and limiting conditions. Following the previous determination of the stoichiometric equations (Spirulina compartment) and regarding the two phototrophic compartments of MELISSA (Rhodospirillaceae and Spirulina), we have first to focus our control study on the growth kinetics for the light source. In this paper, we recall the theoretical equations of microbial growth kinetics and emphasise the problem of the light transfer in a photobioreactor. We present their adaptations to our pilot plant taking into account technological and biological specifics (lamp spectrum, working illuminated volume, growth rate,…). We then develop the principles and structure of the control system and describe tests of both the hardware and software for several steady state configurations.

Engineers have long been restricted in designing and manufacturing one piece, hollow composite components with complex internal geometry. Complex core pulls in the plastic tool, major concessions made in the actual component design or components joined from several pieces were the early means of producing such components. Progressive thinking led to the use of matrix materials such as sand, salt and wax, which provided a measure of flexibility in allowing designed-in undercut areas. These materials, however, lacked the capability to meet the required demands of dimensional accuracy and internal surface, as well as proving themselves unsuitable for high volume production. The concerns for repetitive dimensional accuracy, quality internal surface and high volume production capability has now been satisfied with the use of low melting temperature metal alloys.

This paper presents an innovative brake booster which permits the brake assist function of the electric brake assist system to be implemented with mechanical means. The resultant significant reduction of manufacturing costs enhances the chances for a wide-spread use of this feature in all vehicle classes, thereby making an important contribution to the general improvement of traffic safety. Based on an analysis of the mechanically detectable physical variables for recognizing a panic situation and an evaluation of possible methods of mechanical valve activation, the paper presents a mass production solution and describes its functional properties. In particular, it should be noted that the possibility of controlling the braking pressure within the brake assist function even represents a functional advantage

This paper describes the interrelated controls for automatic start sequencing, fuel scheduling, customer air delivery, and supervisory and protective systems as applied to the Curtiss-Wright CW657E “Jet-Air” Compressor. Model CW657E is capable of delivering 15,000 SCFM air at 85 psig (at 30°F and sea level pressure) and may be used in a diversity of manufacturing, processing, and industrial applications. A description of the control system and its operation in relation to compressor requirements, while furnishing air to feed distribution lines to air assisted water atomizing nozzles for snow making is reviewed as an example. Other models can deliver up to 30,000 SCFM with modified control systems, including pressure controls.

Geometric dimensioning and tolerancing is both a “language” and a “technique.” Its objective is to facilitate design, production, and inspection and, simultaneously, provide the most economic results. This paper describes the implementation and practice to accomplish these through illustrating methods to state design requirements specifically and clearly and to provide for maximum producibility, uniformity of interpretation, etc. The need to reflect a common objective for design, production, and inspection via the stated drawing requirement is emphasized. Application and interpretation of geometric characteristics (emphasizing symbology), fundamentals, rules, etc. are presented. Basis for the content of this paper is USASI Y14.5-1966 “Dimensioning and Tolerancing for Engineering Drawings.”

Driver state monitoring is a crucial technology for enhancing road safety and preventing human error-caused accidents in the era of autonomous vehicles. This paper presents CogniSafe, a comprehensive driver monitoring system that uses deep learning and computer vision methods to detect various types of driver distractions and fatigue. CogniSafe consists of four modules: Driver anomaly detection and classification: A novel two-phase network that proposes and recognizes driver anomalies, such as texting, drinking, and adjusting radios, using multimodal and multiview input. Gaze estimation: A video-based neural network that jointly learns head pose and gaze dynamics, achieving robust and efficient gaze estimation across different head poses. Eye state analysis: A multi-tasking CNN that encodes features from both eye and mouth regions, predicting the percentage of eye closure (PERCLOS) and the frequency of mouth opening (FOM).

This paper, confined to the application of hard chrome plated liners to high-speed four-stroke diesel and gasoline engines, illustrates the increase in their popularity in the United Kingdom, and the advanced production methods which make this economically possible. The need for balanced engine life has long been apparent and is even more important today, the growth of motor transport having outstripped repair facilities. Iron bore life has been surpassed by improvement in the life of other component parts in the modern diesel engine. The provision of hard chrome plated liners can restore the balance. Further development and turbocharging of diesel engines has shown the need for a bore material capable of preventing scuffing and galling at elevated temperatures. Hard chrome has already proved itself in four-stroke engines under these conditions.

The Boeing Company in Mesa, Arizona, has been conducting a concept design study of a roadable helicopter called the “Converticar” to assess its feasibility. This is a twin-engine vehicle with twin retractable coaxial counter-rotating rotors. The purpose of the study is to describe a vehicle that carries four passengers in the equivalent of a luxury car that also can fly like a helicopter, and can be priced like a luxury car. To come near this cost goal, the production rate must be on the order of 500,000 units a year. At that rate there is no chance of training a comparable number of pilots each year. So the machine must fly and navigate autonomously, with the pilot just dialing in where he/she wants to go. Technologically, the concept appears to be feasible. Modern design processes, new materials, and improved manufacturing process should allow the Converticar to be built at the prescribed rate when the proper infrastructure for manufacturing it is made available.

A new truck type street sweeper has been developed which incorporates some of the sweeping advantages of a three wheeled sweeper (tricycle steer) and the transport advantages of a legal highway truck. It offers major productivity improvements through better operator environment and decrease of nonsweeping time in the operational cycle. It is possible for a small “short line” special purpose vehicle manufacturer to develop, test, and produce such a vehicle and meet Federal regulatory requirements with limited “In house” design and testing facilities. Here this was accomplished through judicious augmentation by outside specialized design and testing organizations.

Large scale automotive displays e.g., liquid crystal displays, require chip on glass technology at least for the driver-ICs. In this paper different IC-packages, metallization, bonding and encapsulation techniques are compared and conclusions for production methods are drawn.

In today’s Automotive world, there is NO need to advocate “Light weighting”. Government policies for carbon footprint reduction combined with high safety standards are driving OEMs to adopt advanced manufacturing technologies. Steel hot forming is selected as most preferred way to reduce weight as it is easy to adopt and commercially known. It had many advantages compare to conventional cold stamping of standard and high tensile steel. The process consists of heating blank to nearly 1000 °C and quenching it in tool to for martensitic structure. Higher strength up to 2000 MPa can be achieved by this process. There are many examples where part weight is reduced by 15 to 20 % by this method. But Steel hot forming has limitation as specific density of steel is still high. Thus, there is limitation to its weight reduction capability. For further reduction, OEMs have started exploring Aluminium hot forming.

This paper discusses the use of electromechanical devices as the kinematic portions of a microprocessor based gas turbine control system. Specific applications are: 1. An electric motor driven, positive displacement pump, which provides metered high pressure fuel to the distribution manifold. Fuel metering to be provided by varying the motor angular velocity. 2. An electric motor driven lube oil pump. 3. Electromechnical actuators for motion and control of compressor and power turbine variable geometry. 4. A starter/generator integral with the gas generator. Topics covered include: Comparison to conventional hydro-mechanical systems. Response characteristics of the fuel pump and actuator systems. Brushless D.C. motor characteristics. Power electronics requirements for brushless D.C. motors. Control electronics interface with brushless D.C. motor systems. Reliability and maintainability issues. Diagnostic/prognostic enhancements.

For 1974, Ford Motor Company is providing, as standard equipment, a solid state ignition system on all 400 CID and 460 CID engines as well as on all California vehicles equipped with 200 through 351 CID engines. This paper explains the Ford solid state ignition system and the objectives and design philosophy that was used in the development of the system. Further, a review of the design and production validation test plans is discussed. With this background, specific examples of the effectiveness of complete problem analysis for fundamental cause and corrective action is presented in addition to control methods and evaluation of corrective action. This problem analysis system allowed this automotive electronic product to go into production with a high degree of confidence in meeting the reliability goals.