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Article

Armagan Altinisik and Utku Yildirim

Electrical defects cover an important part of assembly defects and strongly affect the vehicle system performance. Almost 40% of assembly defects are classified as human…

Abstract

Purpose

Electrical defects cover an important part of assembly defects and strongly affect the vehicle system performance. Almost 40% of assembly defects are classified as human errors and electrical connection failures represent a significant part of them. Humans still remain a cost-effective solution for the flexible manufacturing systems with increasing product complexity. So, understanding human behaviors is still a challenging task. The purpose of this study is to define, prioritize and validate the critical factors for the complexity of electrical connector plugin process.

Design/methodology/approach

The critical variables were defined by the expert team members. The required number of measurements and variables were revised resulting preliminary analysis of binary logistic regression. After the revision of measurement plan, the list of critical input variables and the mathematical model were defined. The model has been validated by the fitted values of the residuals (FITS analysis).

Findings

To the best of the authors’ knowledge, this is one of the limited studies, which defines the critical factors for electrical connection process complexity. Female connector harness length, connector width/height/length differences, operator sense of correct connector matching and ergonomy were defined as the factors with the highest impact on the failure occurrence. The obtained regression equation strongly correlates the failure probability.

Practical implications

The obtained mathematical model can be used in new model development processes both for the product and assembly process design (ergonomy, accessibility and lay-out).

Originality/value

The obtained risk factors demonstrated a strong correlation with assembly process complexity and failure rates. The output of this study would be used as an important guide for process (assembly line ergonomy, accessibility and lay-out) and product design in new model development and assembly ramp-up phases.

Details

Assembly Automation, vol. 40 no. 6
Type: Research Article
ISSN: 0144-5154

Keywords

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Article

Mica Grujicic, Jennifer Snipes, S. Ramaswami and Fadi Abu-Farha

The purpose of this paper is to propose a computational approach in order to help establish the effect of various self-piercing rivet (SPR) process and material parameters…

Abstract

Purpose

The purpose of this paper is to propose a computational approach in order to help establish the effect of various self-piercing rivet (SPR) process and material parameters on the quality and the mechanical performance of the resulting SPR joints.

Design/methodology/approach

Toward that end, a sequence of three distinct computational analyses is developed. These analyses include: (a) finite-element modeling and simulations of the SPR process; (b) determination of the mechanical properties of the resulting SPR joints through the use of three-dimensional, continuum finite-element-based numerical simulations of various mechanical tests performed on the SPR joints; and (c) determination, parameterization and validation of the constitutive relations for the simplified SPR connectors, using the results obtained in (b) and the available experimental results. The availability of such connectors is mandatory in large-scale computational analyses of whole-vehicle crash or even in simulations of vehicle component manufacturing, e.g. car-body electro-coat paint-baking process. In such simulations, explicit three-dimensional representation of all SPR joints is associated with a prohibitive computational cost.

Findings

It is found that the approach developed in the present work can be used, within an engineering optimization procedure, to adjust the SPR process and material parameters (design variables) in order to obtain a desired combination of the SPR-joint mechanical properties (objective function).

Originality/value

To the authors’ knowledge, the present work is the first public-domain report of the comprehensive modeling and simulations including: self-piercing process; virtual mechanical testing of the SPR joints; and derivation of the constitutive relations for the SPR connector elements.

Details

Multidiscipline Modeling in Materials and Structures, vol. 10 no. 4
Type: Research Article
ISSN: 1573-6105

Keywords

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Article

Mica Grujicic, Jennifer Snipes and S Ramaswami

The purpose of this paper is to propose a computational approach to establish the effect of various flow drilling screw (FS) process and material parameters on the quality…

Abstract

Purpose

The purpose of this paper is to propose a computational approach to establish the effect of various flow drilling screw (FS) process and material parameters on the quality and the mechanical performance of the resulting FS joints.

Design/methodology/approach

Toward that end, a sequence of three distinct computational analyses is developed. These analyses include: (a) finite-element modeling and simulations of the FS process; (b) determination of the mechanical properties of the resulting FS joints through the use of three-dimensional, continuum finite-element-based numerical simulations of various mechanical tests performed on the FS joints; and (c) determination, parameterization and validation of the constitutive relations for the simplified FS connectors, using the results obtained in (b) and the available experimental results. The availability of such connectors is mandatory in large-scale computational analyses of whole-vehicle crash or even in simulations of vehicle component manufacturing, e.g. car-body electro-coat paint-baking process. In such simulations, explicit three-dimensional representation of all FS joints is associated with a prohibitive computational cost.

Findings

Virtual testing of the shell components fastened using the joint connectors validated the ability of these line elements to realistically account for the strength, ductility and toughness of the three-dimensional FS joints.

Originality/value

The approach developed in the present work can be used, within an engineering-optimization procedure, to adjust the FS process and material parameters (design variables) in order to obtain a desired combination of the FS-joint mechanical properties (objective function).

Details

International Journal of Structural Integrity, vol. 7 no. 3
Type: Research Article
ISSN: 1757-9864

Keywords

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Article

Brian Shepherd

The reliability of an electronic connector is more important now than at any time in the past. Not only has system complexity grown but operating environmental conditions…

Abstract

The reliability of an electronic connector is more important now than at any time in the past. Not only has system complexity grown but operating environmental conditions are more severe and system speed has made circuits less tolerant of any interference. With “fly by wire” aircraft, and fully computer controlled communications systems, even more demanding performance is required. However system reliability is calculated, whether by MIL‐HDBK‐217B, or latest S.A.E. data, or the more traditional MTBF calculations, it is clear that connections form a key part of the total statistics. As a greater number of components have become interconnected, either by rack, module, panel, backplane, or PCB, pin counts on connectors have slowly increased. A connector which only a few years ago would have 160 ways now has 220 or 330 ways. Finally, as component sizes shrink and on‐chip integration grows there is very significant pressure to reduce the size of connectors whilst at the same time further improving reliability.

Details

Aircraft Engineering and Aerospace Technology, vol. 59 no. 5
Type: Research Article
ISSN: 0002-2667

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Article

Makhlouf Derdour, Philippe Roose, Marc Dalmau and Nacira Ghoualmi‐Zine

The purpose of this paper is to present a supervised adaptation platform for applications‐based components.

Abstract

Purpose

The purpose of this paper is to present a supervised adaptation platform for applications‐based components.

Design/methodology/approach

The platform is designed using a model based top‐down approach. The authors use UML diagrams and particularly scenarios and activity diagrams.

Findings

The CSC (component, service and connector) platform is based on a component/service model that allows adaptation of component‐based applications and uses service‐oriented architecture for providing adaptation services to be embedded in adaptation connectors.

Originality/value

The paper proposes CSC, a self‐adaptation platform based on MMSA, to describe software architectures for multimedia‐oriented application and providing adaptation capabilities. The platform is based on services and offer architecture, with three layers particularly adapted to adaptation of multimedia flow (types, formats, properties) and which allows solving the heterogeneity problems of components.

Details

Journal of Systems and Information Technology, vol. 14 no. 1
Type: Research Article
ISSN: 1328-7265

Keywords

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Article

Colin Williamson

A new “backshell to backshell” connector system, the DG 123, that significantly improves corrosion resistance, durability and electromagnetic (EMI) compatibility, while…

Abstract

A new “backshell to backshell” connector system, the DG 123, that significantly improves corrosion resistance, durability and electromagnetic (EMI) compatibility, while also offering weight savings of more than 30% in comparison with standard aluminium connectors, is now gaining considerable acceptance in new aircraft and avionic projects. Applications for this revolutionary approach to the design of circular connectors using “composite” materials and metalisation processes include weapon pylons on carrier borne aircraft — where the DG123 correction system has contributed to a significant improvement on the Mean Time Between Failure (M.T.B.F.) figure. The connectors are also used on missile systems and have recently been approved for use on the United States space station “Freedom”.

Details

Aircraft Engineering and Aerospace Technology, vol. 62 no. 1
Type: Research Article
ISSN: 0002-2667

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Article

Jun Wu, Fenglei Ni, Yuanfei Zhang, Shaowei Fan, Qi Zhang, Jiayuan Lu and Hong Liu

This paper aims to present a smooth transition adaptive hybrid impedance control for compliant connector assembly.

Abstract

Purpose

This paper aims to present a smooth transition adaptive hybrid impedance control for compliant connector assembly.

Design/methodology/approach

The dynamics of the manipulator is firstly presented with linear property. The controller used in connector assembly is inspired by human operation habits in similar tasks. The hybrid impedance control is adopted to apply force in the assembly direction and provide compliance in rest directions. The reference trajectory is implemented with an adaptive controller. Event-based switching strategy is conducted for a smooth transition from unconstrained to constrained space.

Findings

The method can ensure both ideal compliance behaviour with dynamic uncertainty and a smooth transition from unconstrained to constrained space. Also, the method can ensure compliant connector assembly with a good tolerance to the target estimation error.

Practical implications

The method can be applied in the connector assembly by “pushing” operation. The controller devotes efforts on force tracking and smooth transition, having potential applications in contact tasks in delicate environment.

Originality/value

As far as the authors know, the paper is original in providing a uniform controller for improving force and position control performance in both unconstrained and constrained space with dynamic uncertainty. The proposed controller can ensure a smooth transition by only adjusting parameters.

Details

Industrial Robot: An International Journal, vol. 45 no. 2
Type: Research Article
ISSN: 0143-991X

Keywords

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Article

G.R. Wrixon AMRAes

DESPITE having worked in the Aircraft Industry for many years, I had never considered the importance of connectors to the operational efficiency of aircraft. That is…

Abstract

DESPITE having worked in the Aircraft Industry for many years, I had never considered the importance of connectors to the operational efficiency of aircraft. That is, until one dark night when I was driving back into London along the M4 motorway, in the centre lane, at a steady 70mph cruise, the engine suddenly stopped. I declutched, disengaged the gear and coasted on, looking for a gap in the nearside traffic to reach the hard shoulder. When I tried to signal left I realised I had suffered a total electrical failure. After a cold wait the AA man came to my rescue, pulled the loom of wires from the engine bulkhead, cleaned up the pins and replaced it. The engine, lights and indicators sprang back into life. I learned about connectors that night!

Details

Aircraft Engineering and Aerospace Technology, vol. 60 no. 1
Type: Research Article
ISSN: 0002-2667

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Article

P.T. Vianco and A.C. Kilgo

Gold coatings are used on connector structures to maintain suitable solderability of the underlying Ni coating layer as well as to prevent surface corrosion during…

Abstract

Gold coatings are used on connector structures to maintain suitable solderability of the underlying Ni coating layer as well as to prevent surface corrosion during service. However, the likelihood of Au embrittlement in connector solder joints must be minimized by eliminating much of the Au plating from the surfaces using a hot solder dipping or “wicking” procedure prior to final assembly. It was observed that Au removal was most effective by using a double wicking process. Also, a higher soldering temperature improved the efficiency of the Au removal process. A longer soldering time during the wicking process did not appear to offer an appreciable improvement in Au removal. Because the wicking procedure was a manual process, it was found to be operator dependent.

Details

Soldering & Surface Mount Technology, vol. 12 no. 2
Type: Research Article
ISSN: 0954-0911

Keywords

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Article

R. Martens, M. Osterman and D. Haislet

A pressure contact connector design was evaluated based on contact load and tested under temperature cycling. The damageinduced on gold contact surfaces in a pressure…

Abstract

A pressure contact connector design was evaluated based on contact load and tested under temperature cycling. The damage induced on gold contact surfaces in a pressure contact connector was examined using visual inspection methods. The connector was subjected to mating and unmating operations, as well as repeated thermal excursions to determine environmental factors which would accelerate damage. Pressure indentations and wear tracks were found on the contact bumps and fingers resulting from the temperature cycling. This wear of the contact finish could make the connector susceptible to corrosion by exposing the base metal after repeated thermal cycling. Wear was assumed to be induced due to insufficient contact pressure between the electrical contacts. An alternative design was examined using finite element analysis which appears to provide a high contact load which should result in a lower contact resistance and less wear.

Details

Circuit World, vol. 23 no. 3
Type: Research Article
ISSN: 0305-6120

Keywords

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