The Jucam 1S grinds cam pieces using a double workhead with two clamping fixtures. It can be swiveled 180° to an exact end position. The workpiece transfers from its loading position to the grinding position using an automated process. Simultaneously, the second workpiece transitions from the grinding to the discharge position. The grinding machine specializes in package grinding of single cams.
When grinding, the machine clamps the cam pieces using an inner clamping mandrel to ensure precise angular reference to inner teeth.
The machine compensates for material deviations and variables such as fluctuations in temperature, guaranteeing a constant standard for components.
It’s marketing 101 – take your opponent’s perceived strengths and portray them as weaknesses.
Ford’s decision for the 2015 model year to replace steel in F-150 pickup body panels with aluminum was a huge success. Shaving weight meant towing, payload, and fuel efficiency improved. Across town, General Motors’ marketing folks responded with ads showing how rugged their steel-bedded Chevy Silverado pickups were.
In commercials, front-end loaders dumped boulders into the beds of pickups, leading to dents and tears in the Ford aluminum panels and dusty-but-unharmed steel Silverado pickup beds.
The clear message – tough steel makes a tough truck, not recycled beer cans.
So why does the 2019 Silverado have more aluminum than the outgoing model?
Throughout the past decade, weight has become Enemy No. 1 of nearly every automotive and commercial truck. In consumer cars, less weight means better fuel economy. For trucks, the lower the weight of the body, the more capability companies can offer in towing, pulling, and carrying. Ford’s aluminum-bodied F-150 didn’t succeed by offering minor fuel-economy improvements. The pickup dominated the market because its working statistics improved.
With the Silverado, GM is splitting the difference for now. The truck’s hood has been made from aluminum for several generations, but the 2019 model also features aluminum tailgates and side doors. Pierre Labat, vice president of global automotive for Novelis Aluminum, discusses the growing use of aluminum for hang-on panels such as doors in the 2018 outlook story, starting on page 16. The Silverado’s bed is made from advanced high-strength steel, offering durability figures that will be sure to show up in future TV commercials, while still cutting vehicle weight.
The result – GM’s 2019 trucks are 400 lb lighter than the outgoing models. That’s short of the 732 lb savings Ford earned from going all aluminum, but it should be enough to boost those essential work numbers.
A few years ago, industry rumors had GM following Ford’s lead – going aluminum for nearly the entire truck body. Did the commercials back designers into a corner by convincing some buyers that steel is better? Was the decision entirely cost based (steel is still about one-third the price of aluminum)? Or is the steel bed an interim step?
Leaked reports from GM’s design studio have the automaker experimenting with light, ultra-strong composites for future truck beds. Honda’s Ridgeline pickup boasts a composite bed that’s lighter than metal options, corrosion free, cleanable with a hose, and easy to fill with ice to cool beverages while tailgating.
For suppliers, the takeaway is clear but far from simple. Lightweighting is still a driving force in automotive design, but there are many ways to shave pounds. It’s not just a question of steel, aluminum, or composites; virtually every future vehicle will be an increasingly complex mix of low-cost, lightweight, and high-performance materials. That’s going to require everyone in the industry, from suppliers to those of us in the trade press, to be versed in a wider array of options.
The CVG series vertical universal cylindrical grinding machine with pallet changer – available in three part-swing diameter sizes 25.5", 37.5", and 53" – grinds the OD, ID, and faces in one part chucking with machine roundness accuracy of less than 0.00004". Standard frequency, twin opposing wheel spindles feature a larger heavy-duty spindle dedicated to OD and face grinding (using a 14" diameter wheel) and a smaller spindle for ID and face grinding.
All CVG machines come with a six place automatic tool charger using the HSK-E100 type quill clamping system. Large numbers of stored and qualified wheels reduce setup time and improve part quality so complicated parts can be completed in one chucking. Grinding wheel loading and unloading is through the ergonomically positioned side door of the enclosure.
Taiyo Koki Grinding Machine Co. A DMG MORI company
A carbide step drill program features Drill-Chamfer tools available in a full range of sizes online from stock.
The high-penetration rate solid carbide EF Step Drill drills and chamfers in one operation, saving time and providing more accurate hole-to-chamfer location and optimal hole preparation for tapping or thread milling. Tools feature a double margin design on the minor diameter for the roundest threaded hole size, and the web construction is adjusted for each diameter for efficient chip evacuation.
It includes sizes from 2.8mm to 15.5mm minor diameter, UNC/UNF, and a full-size range in 2XD and 3.5XD lengths. Tools are coolant-thru, 4-margin designed with TiAIN-T14 coating, can cut a range of materials, and are available in cut or form thread diameters.
The LEXT OLS5000 3D laser confocal scanning microscope offers imaging quality and acquires data 4x faster, improving user experience with automated software.
An optional expansion frame and long working distance (LWD) lens measure samples up to 210mm high and concavities up to 25mm deep. With the stitching function, the microscope can expand field of view (FOV) by connecting up to 2,500 images together.
A 10x lens, optimized for a 405nm-wavelength light source, and a long working distance lens reduces aberration and enables accurate measurements across the entire field of view. 4K scanning technology, with a resolution of 4,096 pixels in the X direction, enhances resolution and improves shape measurement reliability.
The low energy integrated circuit (IC) is compliant with the Bluetooth Low Energy (LE) core specification 4.2 – including support for a secure connection, LE privacy features, and extended packet length. Designed for use in automotive environments, it contains analog radio frequency and baseband digital parts, providing a solution in a low-profile (40-pin 6mm x 6mm x 1mm) QFN wettable flank package with a pin pitch of 0.5mm. The package supports automatic visual inspection.
The device provides Bluetooth Host Control Interface (HCI) and low energy generic attribute profile functions. The IC becomes an application processor when used with external non-volatile memory. It can also be used with an external host processor. By providing a wireless connection to sensors, the IC can be used in remote key systems and other applications, reducing cabling.
The 10Gbps automotive Ethernet backbone solution integrates reliable signal integrity, prioritization, scalability, and security.
The end-to-end Ethernet-based solution operates at high bandwidth across multiple hardware and software components. With secure over-the-air updateability for software and firmware, the solution helps avoid vehicle recalls and enables in-vehicle diagnostics over Internet protocol. Molex LLC
PART 2 OF A 2-PART SERIES Part 1 in the October issue of Today’s Motor Vehicles looked at how poor indoor air quality (IAQ) can negatively impact productivity, product quality, and worker health. Part 2 covers IAQ mitigation options and the benefits of implementing a qualified, well-designed system.
Appropriate indoor air quality (IAQ) engineering controls are essential to protect worker health and maintain regulatory compliance. There are a lot of options for automotive manufacturers when it comes to dust and fume collection, from ambient air filtration systems to an array of source capture options. The best solution for any manufacturer depends on a combination of processes and facility characteristics.
IAQ mitigation options
No matter the processes used, IAQ mitigation options fall into a few broad categories. Manufacturers can think of these along a two-dimensional matrix:
Filtration vs. exhaust: Exhaust and makeup air systems push dirty air out of the facility and pull clean(er) air in. If particulate volumes are low, and heating and cooling costs are not a consideration, this option is inexpensive and easy to implement. However, if makeup air must be heated or cooled to indoor temperatures, exhaust systems can drain energy budgets. Depending on the type and volume of particulates, they may also put the facility out of environmental compliance. Filtration systems pull dirty air into a dust collector where particulates are filtered out before clean air is returned to the facility. Filtration is usually the better option for facilities with high volumes of particulates and temperature-controlled indoor environments.
Source capture vs. ambient: Source capture systems collect particulates close to the source as they are generated, before they escape into the ambient air. Ambient systems turn over air for the entire facility, suitable for automotive manufacturing processes that do not produce a large volume of particulates. For processes that produce larger volumes of particulates, source capture will be cheaper when it is feasible; the less air needed to move, the lower equipment and operating costs will be. Ambient systems can also be used with source capture solutions for secondary air quality control.
Source capture is the best option for many automotive manufacturing processes, especially Tier I and Tier II suppliers manufacturing smaller parts. The best option depends on the type of process (e.g. dust-producing processes such as cutting and grinding, or fume-producing processes such as welding and plastic molding), the volume of particulates, the size of components, and whether human exposure is a concern.
Hoods and canopies can be placed over top of equipment such as robotic welders, injection molding machines, and laser cutting stations. Dust and fumes are contained within the enclosures, making it easy to capture and collect.
Fume arms use directed airflow to pull contaminated air from the immediate area. They work best for weld fumes and other thermally-generated fumes that rise in the air. Fume arms have a narrow collection zone, so they should be used for small, stationary components that allow the arm to be close to the source.
Backdraft or downdraft tables work well for manual grinding, cutting, or small-component welding. Like fume arms, backdraft intakes are best for thermal fumes. Downdraft tables can collect heavier dusts that tend to fall.
Fume guns offer source capture for many manual welding applications. They add fume extraction to the tip of the welding torch, so fumes are collected where they are generated.
Ambient filtration can be used as a stand-alone system when working with larger components that cannot be hooded, or as part of a hybrid system that also includes source capture. There are three main options for ambient filtration systems.
Ducted push-pull systems rely on a system of ducts near the ceiling that creates air currents in the building, moving air across the area. This continually dilutes the contaminated air with filtered air.
Ductless systems rely on standalone dust collectors that sit on the factory floor, creating their own circular local airflow patterns, pulling dirty air in and pushing clean air out. These are easier to install since they do not require overhead ductwork, but they do require some floor space.
Ductless, ceiling mounted systems, such as the RoboVent Vista360, combine ductless systems with the floor space savings of a traditional push-pull system and may work better in facilities with overhead cranes.
For each manufacturing process used in motor vehicle construction, there is a matching IAQ solution.
Welding: High-production robotic welding of smaller automotive parts is usually done under a hood. For larger weldments, robotic fume extraction is sometimes an option. However, resistance welding of frames and body components generally requires an ambient solution. Manual welding for small parts can be done on a backdraft table or beneath a fume arm to pull fumes away from the welder. For large manual weldments, a fume gun like the RoboVent Extractor may be best.
Machining: Machining precision automotive components usually involves lubricants. Metalworking fluids can create dangerous oil mists when heated by high-speed machining processes. Specialized collection equipment and filters must be used for oil mists as regular filters quickly become saturated and ineffective when oil mists mix with dry particulate. Packed-bed filters, also called coalescing filters, are most effective for most oil mists.
Cutting and grinding: Downdraft tables are effective for most manual cutting and grinding. Laser and plasma cutting produce large volumes of dust that must be controlled to avoid damaging equipment and to reduce combustion hazards. A hooded enclosure, ducted to a high-powered dust collector, can keep dusts under control.
Thermoplastic injection molding: IAQ planning must consider the process from raw material handling to final production of components. Plastic dusts are dangerous and combustible, so preventing buildup in the air is essential. High-powered ventilation can clean the air in areas where raw pellets or powders are moved, poured, mixed, and processed. If dusts can be contained to a smaller area, source capture filtration systems can use an intake plenum or hood over the processing point, ducted to an NFPA-compliant dust collector. Employees working inside the enclosed area should wear personal protection when working directly with the materials. Molding produces fumes rather than dusts, so an ambient filtration system can collect fumes as they rise. If the plastic processing area cannot be fully enclosed, partitioning and negative air pressure can create local containment, preventing fumes from escaping.
Rubber manufacturing: Ambient filtration is generally needed for rubber manufacturing to satisfy health and safety and environmental regulations regarding volatile organic compounds. Source capture can sometimes be used for enclosed processes.
An experienced air quality engineer can help manufacturers find the best solution for their specific applications and challenges. Computer modeling can help companies avoid over- or under-engineering solutions in cost and effectiveness.
RoboVent’s VentMapping process optimizes placement of source and ambient capture equipment to meet the company’s air quality goals. Questions to ask during this process include:
What processes are used (e.g. machining, injection molding, grinding and polishing, welding), and what is the volume of particulates produced?
What are the sizes of components? Can processes be contained under a hood or on a bench?
Are processes manual or robotic?
When, where, and how are humans exposed to particulates?
What is the chemical makeup of the particulates, and what are the permissible exposure limits (PELs)?
Are the particulates combustible?
Where are the particulates generated, where do they end up in the facility?
What are the facility’s airflow patterns, and what factors influence them (e.g. HVAC or ventilation systems, facility layout, etc.)?
What mitigation systems are in place already, and how are they working?
How much flexibility is needed to reconfigure manufacturing lines?
Maintaining a safe and healthy manufacturing environment shouldn’t break the bank. A strategic approach to air quality system design can help vehicle makers get the best value for their money and take IAQ off their list of things to worry about.