Enhanced descriptions from Syndetics:

Addressing design for automated and manual assembly processes, Assembly Automation and Product Design, Second Edition examines assembly automation in parallel with product design. The author enumerates the components, processes, performance, and comparative economics of several types of automatic assembly systems. He provides information on equipment such as transfer devices, parts feeders, feed tracks, placing mechanisms, and robots.

Presenting detailed discussions of product design for assembly, the book contains over 500 drawings, tables, and equations, and numerous problems and laboratory experiments that help clarify and reinforce essential concepts. Highlighting the importance of well-designed products, the book covers design for manual assembly, high-speed automatic and robot assembly, and electronics assembly. The new edition includes the popular Handbook of Feeding and Orienting Techniques for Small Parts, published at the University of Massachusetts, as an appendix. This provides more than 100 pages packed with useful data and information that will help you avoid the costly errors that often plague high-volume manufacturing companies.

In today's extremely competitive, highly unpredictable world, your organization needs to constantly find new ways to deliver value. Performing the same old processes in the same old ways is no longer a viable option. Taking an analytical yet practical approach to assembly automation, this completely revised second edition gives you the skill set you need not only to deliver that value, but to deliver it economically and on time.

Table of contents provided by Syndetics

• Chapter 1 Introduction (p. 1)
• 1.1 Historical Development of the Assembly Process (p. 2)
• 1.2 Choice of Assembly Method (p. 6)
• 1.3 Social Effects of Automation (p. 10)
• References (p. 15)
• Chapter 2 Automatic Assembly Transfer Systems (p. 17)
• 2.1 Continuous Transfer (p. 17)
• 2.2 Intermittent Transfer (p. 17)
• 2.3 Indexing Mechanisms (p. 23)
• 2.4 Operator-Paced Free-Transfer Machine (p. 27)
• References (p. 28)
• Chapter 3 Automatic Feeding and Orienting - Vibratory Feeders (p. 29)
• 3.1 Mechanics of Vibratory Conveying (p. 29)
• 3.2 Effect of Frequency (p. 34)
• 3.3 Effect of Track Acceleration (p. 34)
• 3.4 Effect of Vibration Angle (p. 35)
• 3.5 Effect of Track Angle (p. 35)
• 3.6 Effect of Coefficient of Friction (p. 37)
• 3.7 Estimating the Mean Conveying Velocity (p. 38)
• 3.8 Load Sensitivity (p. 42)
• 3.9 Solutions to Load Sensitivity (p. 44)
• 3.10 Spiral Elevators (p. 46)
• 3.11 Balanced Feeders (p. 47)
• 3.12 Orientation of Parts (p. 47)
• 3.13 Typical Orienting System (p. 48)
• 3.14 Effect of Active Orienting Devices on Feed Rate (p. 54)
• 3.15 Analysis of Orienting Systems (p. 55)
• 3.15.1 Orienting System (p. 57)
• 3.15.2 Method of System Analysis (p. 58)
• 3.15.3 Optimization (p. 61)
• 3.16 Performance of an Orienting Device (p. 63)
• 3.16.1 Analysis (p. 63)
• 3.17 Natural Resting Aspects of Parts for Automatic Handling (p. 69)
• 3.17.1 Assumptions (p. 70)
• 3.17.2 Analysis for Soft Surfaces (p. 71)
• 3.17.3 Analysis for Hard Surfaces (p. 77)
• 3.17.4 Analysis for Cylinders and Prisms with Displaced Centers of Mass (p. 78)
• 3.17.5 Summary of Results (p. 78)
• 3.18 Analysis of a Typical Orienting System (p. 78)
• 3.18.1 Design of Orienting Devices (p. 85)
• 3.19 Out-of-Bowl Tooling (p. 87)
• References (p. 89)
• Chapter 4 Automatic Feeding and Orienting - Mechanical Feeders (p. 91)
• 4.1 Reciprocating-Tube Hopper Feeder (p. 92)
• 4.1.1 General Features (p. 94)
• 4.1.2 Specific Applications (p. 94)
• 4.2 Centerboard Hopper Feeder (p. 94)
• 4.2.1 Maximum Track Inclination (p. 94)
• 4.2.2 Load Sensitivity and Efficiency (p. 99)
• 4.3 Reciprocating-Fork Hopper Feeder (p. 100)
• 4.4 External Gate Hopper Feeder (p. 102)
• 4.4.1 Feed Rate (p. 102)
• 4.4.2 Load Sensitivity and Efficiency (p. 106)
• 4.5 Rotary-Disk Feeder (p. 108)
• 4.5.1 Indexing Rotary-Disk Feeder (p. 108)
• 4.5.2 Rotary-Disk Feeder with Continuous Drive (p. 109)
• 4.5.3 Load Sensitivity and Efficiency (p. 110)
• 4.6 Centrifugal Hopper Feeder (p. 110)
• 4.6.1 Feed Rate (p. 111)
• 4.6.2 Efficiency (p. 114)
• 4.7 Stationary-Hook Hopper Feeder (p. 115)
• 4.7.1 Design of the Hook (p. 115)
• 4.7.2 Feed Rate (p. 118)
• 4.8 Bladed-Wheel Hopper Feeder (p. 119)
• 4.9 Tumbling-Barrel Hopper Feeder (p. 119)
• 4.9.1 Feed Rate (p. 121)
• 4.10 Rotary-Centerboard Hopper Feeder (p. 124)
• 4.11 Magnetic-Disk Feeder (p. 124)
• 4.12 Elevating Hopper Feeder (p. 125)
• 4.13 Magnetic Elevating Hopper Feeder (p. 126)
• 4.14 Magazines (p. 126)
• References (p. 130)
• Chapter 5 Feed Tracks, Escapements, Parts-Placement Mechanisms, and Robots (p. 131)
• 5.1 Gravity Feed Tracks (p. 131)
• 5.1.1 Analysis of Horizontal-Delivery Feed Track (p. 132)
• 5.1.2 Example (p. 137)
• 5.1.3 On/Off Sensors (p. 139)
• 5.1.3.1 Theory (p. 140)
• 5.1.4 Feed Track Section (p. 143)
• 5.1.5 Design of Gravity Feed Tracks for Headed Parts (p. 146)
• 5.1.5.1 Analysis (p. 146)
• 5.1.5.2 Results (p. 153)
• 5.1.5.3 Procedure for Use of Figure 5.17 to Figure 5.20 (p. 158)
• 5.2 Powered Feed Tracks (p. 158)
• 5.2.1 Example (p. 160)
• 5.3 Escapements (p. 161)
• 5.3.1 Ratchet Escapements (p. 162)
• 5.3.2 Slide Escapements (p. 164)
• 5.3.3 Drum Escapements (p. 165)
• 5.3.4 Gate Escapements (p. 167)
• 5.3.5 Jaw Escapements (p. 167)
• 5.4 Parts-Placing Mechanisms (p. 168)
• 5.5 Assembly Robots (p. 171)
• 5.5.1 Terminology (p. 171)
• 5.5.2 Advantages of Robot Assembly (p. 172)
• 5.5.3 Magazines (p. 174)
• 5.5.4 Types of Magazine Systems (p. 175)
• 5.5.5 Automatic Feeders for Robot Assembly (p. 175)
• 5.5.6 Economics of Part Presentation (p. 178)
• 5.5.7 Design of Robot Assembly Systems (p. 182)
• References (p. 186)
• Chapter 6 Performance and Economics of Assembly Systems (p. 187)
• 6.1 Indexing Machines (p. 187)
• 6.1.1 Effect of Parts Quality on Downtime (p. 187)
• 6.1.2 Effects of Parts Quality on Production Time (p. 188)
• 6.1.3 Effect of Parts Quality on the Cost of Assembly (p. 190)
• 6.2 Free-Transfer Machines (p. 195)
• 6.2.1 Performance of a Free-Transfer Machine (p. 196)
• 6.2.2 Average Production Time for a Free-Transfer Machine (p. 200)
• 6.2.3 Number of Personnel Needed for Fault Correction (p. 200)
• 6.3 Basis for Economic Comparisons of Automation Equipment (p. 201)
• 6.3.1 Basic Cost Equations (p. 202)
• 6.4 Comparison of Indexing and Free-Transfer Machines (p. 204)
• 6.4.1 Indexing Machine (p. 204)
• 6.4.2 Free-Transfer Machine (p. 205)
• 6.4.3 Effect of Production Volume (p. 205)
• 6.5 Economics of Robot Assembly (p. 207)
• 6.5.1 Parts Presentation (p. 208)
• 6.5.2 Profile of Typical Candidate Assembly (p. 211)
• 6.5.3 Single-Station Systems (p. 212)
• 6.5.3.1 Equipment Costs (p. 212)
• 6.5.3.2 Personnel Costs (p. 213)
• 6.5.3.3 Parts Quality (p. 213)
• 6.5.3.4 Basic Cost Equation (p. 214)
• 6.5.4 Multistation Transfer Systems (p. 215)
• 6.5.4.1 Equipment Costs (p. 215)
• 6.5.4.2 Cost Equation (p. 216)
• References (p. 217)
• Chapter 7 Design for Manual Assembly (p. 219)
• 7.1 Introduction (p. 219)
• 7.2 Where Design for Assembly Fits in the Design Process (p. 219)
• 7.3 General Design Guidelines for Manual Assembly (p. 221)
• 7.3.1 Design Guidelines for Part Handling (p. 221)
• 7.3.2 Design Guidelines for Insertion and Fastening (p. 222)
• 7.4 Development of a Systematic DFA Analysis Method (p. 227)
• 7.5 DFA Index (p. 229)
• 7.6 Classification System for Manual Handling (p. 230)
• 7.7 Classification System for Manual Insertion and Fastening (p. 233)
• 7.8 Effect of Part Symmetry on Handling Time (p. 236)
• 7.9 Effect of Part Thickness and Size on Handling Time (p. 237)
• 7.10 Effect of Weight on Handling Time (p. 239)
• 7.11 Parts Requiring Two Hands for Manipulation (p. 240)
• 7.12 Effects of Combinations of Factors (p. 240)
• 7.13 Threaded Fasteners (p. 240)
• 7.14 Effects of Holding Down (p. 242)
• 7.15 Problems with Manual Assembly Time Standards (p. 242)
• 7.16 Application of the DFA Method (p. 244)
• 7.16.1 Results of the Analysis (p. 248)
• 7.17 Further General Design Guidelines (p. 251)
• References (p. 254)
• Chapter 8 Product Design for High-Speed Automatic Assembly and Robot Assembly (p. 257)
• 8.1 Introduction (p. 257)
• 8.2 Design of Parts for High-Speed Feeding and Orienting (p. 258)
• 8.3 Example (p. 263)
• 8.4 Additional Feeding Difficulties (p. 265)
• 8.5 High-Speed Automatic Insertion (p. 266)
• 8.6 Example (p. 269)
• 8.7 Analysis of an Assembly (p. 271)
• 8.8 General Rules for Product Design for Automation (p. 272)
• 8.9 Design of Parts for Feeding and Orienting (p. 276)
• 8.10 Summary of Design Rules for High-Speed Automatic Assembly (p. 280)
• 8.10.1 Rules for Product Design (p. 280)
• 8.10.2 Rules for the Design of Parts (p. 280)
• 8.11 Product Design for Robot Assembly (p. 281)
• 8.11.1 Summary of Design Rules for Robot Assembly (p. 287)
• References (p. 289)
• Chapter 9 Printed-Circuit-Board Assembly (p. 291)
• 9.1 Introduction (p. 291)
• 9.2 Terminology (p. 291)
• 9.3 Assembly Process for PCBs (p. 292)
• 9.4 SMD Technology (p. 301)
• 9.5 Estimation of PCB Assembly Costs (p. 302)
• 9.6 Worksheet and Database for PCB Assembly Cost Analysis (p. 303)
• 9.6.1 Instructions (p. 303)
• 9.7 PCB Assembly - Equations and Data for Total Operation Cost (p. 305)
• 9.7.1 Manual (p. 306)
• 9.7.2 Autoinsertion Machine (p. 306)
• 9.7.3 Robot Insertion Machine (p. 306)
• 9.8 Glossary of Terms (p. 308)
• References (p. 310)
• Chapter 10 Feasibility Study for Assembly Automation (p. 311)
• 10.1 Machine Design Factors to Reduce Machine Downtime Due to Defective Parts (p. 312)
• 10.2 Feasibility Study (p. 313)
• 10.2.1 Precedence Diagrams (p. 314)
• 10.2.2 Manual Assembly of Plug (p. 317)
• 10.2.3 Quality Levels of Parts (p. 318)
• 10.2.4 Parts Feeding and Assembly (p. 319)
• 10.2.5 Special-Purpose Machine Layout and Performance (p. 321)
• 10.2.5.1 Indexing Machine (p. 321)
• 10.2.5.2 Free-Transfer Machine (p. 324)
• 10.2.6 Robot Assembly of the Power Plug (p. 326)
• References (p. 332)
• Problems (p. 333)
• Appendix A Simple Method for the Determination of the Coefficient of Dynamic Friction (p. 363)
• A.1 The Method (p. 363)
• A.2 Analysis (p. 365)
• A.3 Precision of the Method (p. 366)
• A.4 Discussion (p. 366)
• Reference (p. 368)
• Appendix B Out-of-Phase Vibratory Conveyors (p. 369)
• B.1 Out-of-Phase Conveying (p. 370)
• B.2 Practical Applications (p. 372)
• Reference (p. 373)
• Appendix C Laboratory Experiments (p. 375)
• C.1 Performance of a Vibratory-Bowl Feeder (p. 375)
• C.1.1 Objectives (p. 375)
• C.1.2 Equipment (p. 375)
• C.1.3 Procedure (p. 375)
• C.1.4 Theory (p. 376)
• C.1.5 Presentation of Results (p. 378)
• C.2 Performance of a Horizontal-Delivery Gravity Feed Track (p. 379)
• C.2.1 Objectives (p. 379)
• C.2.2 Equipment (Objective 1) (p. 379)
• C.2.3 Theory (Objective 1) (p. 380)
• C.2.4 Procedure (Objective 1) (p. 381)
• C.2.5 Results (Objective 1) (p. 381)
• C.2.6 Equipment (Objective 2) (p. 381)
• C.2.7 Theory (Objective 2) (p. 382)
• C.2.8 Procedure (Objective 2) (p. 382)
• C.2.9 Results (Objective 2) (p. 383)
• C.2.10 Conclusions (p. 383)
• Appendix D Feeding and Orienting Techniques for Small Parts (p. 385)
• D.1 Coding System (p. 385)
• D.1.1 Introduction to the Coding System (p. 386)
• D.1.2 Coding Examples (p. 390)
• D.1.3 Sample Parts for Practice (p. 392)
• D.1.4 Analysis of the Coding of the Sample Parts (p. 393)
• D.1.5 Coding System for Small Parts (p. 395)
• D.2 Feeding and Orienting Techniques (p. 408)
• D.3 Orienting Devices for Vibratory-Bowl Feeders (p. 474)
• D.4 Nonvibratory Feeders (p. 492)
• Nomenclature (p. 501)
• Index (p. 507)