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带式输送机的外文文献翻译.docx

带式输送机的外文文献翻译

IntJAdvManufTechnol（2005）25:

551–559

DOI10.1007/s00170-003-1843-3

——————————————————————————————————————————————————————————————————

S.H.Masood·B.Abbas·E.Shayan·A.Kara

Aninvestigationintodesignandmanufacturingofmechanicalconveyorssystems

forfoodprocessing

Received:

29March2003/Accepted:

21June2003/Publishedonline:

23June2004

Springer-VerlagLondonLimited2004

AbstractThispaperpresentstheresultsofaresearchinvesti-

gationundertakentodevelopmethodologiesandtechniquesthat

willreducethecostandtimeofthedesign,manufacturingand

assemblyofmechanicalconveyorsystemsusedinthefoodand

beverageindustry.Theimprovedmethodologyfordesignand

productionofconveyorcomponentsisbasedontheminimisa-

tionofmaterials,partsandcosts,usingtherulesofdesignfor

manufactureanddesignforassembly.Resultsobtainedonatest

conveyorsystemverifythebeneﬁtsofusingtheimprovedtech-

niques.Theoverallmaterialcostwasreducedby19%andthe

overallassemblycostwasreducedby20%comparedtoconven-

tionalmethods.

KeywordsAssembly·Costreduction·Design·DFA·DFM·

Mechanicalconveyor

1Introduction

Conveyorsystemsusedinthefoodandbeverageindustryare

highlyautomatedcustommadestructuresconsistingofalarge

numberofpartsanddesignedtocarryproductssuchasfood

cartons,drinkbottlesandcansinfastproductionandassembly

lines.Mostoftheprocessingandpackagingoffoodanddrinkin-

volvecontinuousoperationswherecartons,bottlesorcansarere-

quiredtomoveatacontrolledspeedforﬁllingorassemblyoper-

ations.Theiroperationsrequirehighlyefﬁcientandreliableme-

chanicalconveyors,whichrangefromoverheadtypestoﬂoor-

mountedtypesofchain,rollerorbeltdrivenconveyorsystems.

Inrecentyears,immensepressurefromclientsforlowcost

butefﬁcientmechanicalconveyorsystemshaspushedcon-

veyormanufacturerstoreviewtheircurrentdesignandassembly

methodsandlookatanalternativemeanstomanufacturemore

economicalandreliableconveyorsfortheirclients.Atpresent,

S.H.Masood（u）·B.Abbas·E.Shayan·A.Kara

IndustrialResearchInstituteSwinburne,

SwinburneUniversityofTechnology,

Hawthorn,Melbourne3122,Australia

E-mail:

****************.au

mostmaterialhandlingdevices,bothhardwareandsoftware,are

highlyspecialised,inﬂexibleandcostlytoconﬁgure,installand

maintain[1].Conveyorsareﬁxedintermsoftheirlocationsand

theconveyorbeltsaccordingtotheirsynchronisedspeeds,mak-

inganychangeoveroftheconveyorsystemverydifﬁcultandex-

pensive.Intoday’sradicallychangingindustrialmarkets,thereis

aneedtoimplementanewmanufacturingstrategy,anewsystem

operationalconceptandanewsystemcontrolsoftwareandhard-

waredevelopmentconcept,thatcanbeappliedtothedesignof

anewgenerationofopen,ﬂexiblematerialhandlingsystems[2].

HoandRanky[3]proposedanewmodularandreconﬁgurable

2Dand3Dconveyorsystem,whichencompassesanopenre-

conﬁgurablesoftwarearchitecturebasedontheCIM-OSA（open

systemarchitecture）model.Itisnotedthattheresearchinthe

areaofimprovementofconveyorsystemsusedinbeveragein-

dustryisverylimited.Mostofthepublishedresearchisdirected

towardsimprovingtheoperationsofconveyorsystemsandinte-

grationofsystemtohighlysophisticatedsoftwareandhardware.

Thispaperpresentsaresearchinvestigationaimedatim-

provingthecurrenttechniquesandpracticesusedinthede-

sign,manufacturingandassemblyofﬂoormountedtypechain

drivenmechanicalconveyorsinordertoreducethemanufactur-

ingleadtimeandcostforsuchconveyors.Applyingthecon-

ceptofconcurrentengineeringandtheprinciplesofdesignfor

manufacturinganddesignforassembly[4,5],severalcritical

conveyorpartswereinvestigatedfortheirfunctionality,material

suitability,strengthcriterion,costandeaseofassemblyinthe

overallconveyorsystem.Thecriticalpartsweremodiﬁedand

redesignedwithnewshapeandgeometry,andsomewithnew

materials.Theimproveddesignmethodsandthefunctionalityof

newconveyorpartswereveriﬁedandtestedonanewtestcon-

veyorsystemdesigned,manufacturedandassembledusingthe

newimprovedparts.

2Designformanufacturingandassembly（DFMA）

Inrecentyears,researchintheareaofdesignformanufacturing

andassemblyhasbecomeveryusefulforindustriesthatarecon-

552

sideringimprovingtheirfacilitiesandmanufacturingmethodol-

ogy.However,therehasnotbeenenoughworkdoneinthearea

ofdesignforconveyorcomponents,especiallyrelatedtotheis-

sueofincreasingnumbersofdrawingdataandre-engineering

oftheprocessofconveyordesignbasedontraditionalmethods.

Emphasisestandardisation

Usethesimplestpossibleoperations

Useoperationsofknowncapability

Minimisesetupsandinterventions

Undertakeengineeringchangesinbatches

Avastamountofpapershavebeenpublishedthathaveinvesti-

gatedissuesrelatedtoDFMAandappliedtovariousmethodolo-

giestoachieveresultsthatprovedeconomical,efﬁcientandcost

effectiveforthecompaniesunderinvestigation.

ThemainclassiﬁcationsofDFMAknowledgecanbeiden-

tiﬁedas

（1）Generalguidelines,

（2）Company-speciﬁcbestprac-

ticeor（3）Processandorresource-speciﬁcconstraints.General

guidelinesrefertogenerallyapplicablerules-of-thumb,relat-

ingtoamanufacturingdomainofwhichthedesignershould

beaware.ThefollowinglisthasbeencompiledforDFM

guidelines[6].

Thesedesignguidelinesshouldbethoughtofas“optimal

suggestions”.Theytypicallywillresultinahigh-quality,low-

cost,andmanufacturabledesign.Occasionallycompromises

mustbemade,ofcourse.Inthesecases,ifaguidelinegoes

againstamarketingorperformancerequirement,thenextbest

alternativeshouldbeselected[7].

Company-speciﬁcbestpracticereferstothein-housedesign

rulesacompanydevelops,usuallyoveralongperiodoftime,and

whichthedesignerisexpectedtoadhereto.Thesedesignrules

areidentiﬁedbythecompanyascontributingtoimprovedquality

andefﬁciencybyrecognisingtheoverallrelationshipsbetween

Designforaminimumnumberofparts

Developamodulardesign

Minimisepartvariations

Designpartstobemultifunctional

Designpartsformultiuse

Designpartsforeaseoffabrication

Avoidseparatefasteners

Maximisecompliance:

designforeaseofassembly

Minimisehandling:

designforhandlingpresentation

Evaluateassemblymethods

Eliminateadjustments

Avoidﬂexiblecomponents:

theyaredifﬁculttohandle

Usepartsofknowncapability

Allowformaximumintoleranceofparts

Useknownandprovenvendorsandsuppliers

Usepartsatderatedvalueswithnomarginaloverstress

Minimisesubassemblies

particularprocessesanddesigndecisions.Companiesusesuch

guidelinesaspartofthetraininggiventodesignersofproducts

requiringsigniﬁcantamountsofmanualassemblyormainte-

nance.Notethatmostofthemethodologiesaregoodateither

beingquickandeasytostartorbeingmoreformalandquanti-

tative.Forexample,guidelinesbyBoothroydandDewhurst[8]

onDFAareconsideredasbeingquantitativeandsystematic.

WhereastheDFMguidelines,whicharemerelyrulesofthumb

derivedfromexperiencedprofessionals,aremorequalitativeand

lessformal[9].

3Conventionalconveyorsystemdesign

Designandmanufacturingofconveyorsystemsisaverycom-

plexandtime-consumingprocess.Aseveryconveyorsystemis

acustom-madeproduct,eachprojectvariesfromeveryother

projectintermsofsize,productandlayout.Thesystemdesign

Fig.1.Layoutofconveyorsys-

temforlabellingplasicbottles

553

isbasedonclientrequirementsandproductspeciﬁcations.More-

over,thesystemlayouthastoﬁtinthespaceprovidedbythe

company.Theprocessofdesigningalayoutforaconveyorsys-

teminvolverevisionsandcouldtakefromdaystomonthsorin

someinstancesyears.Onewiththeminimumcostandmaximum

clientsuitabilityismostlikelytogetapproval.

Figure1showsaschematiclayoutofatypicalconveyor

systeminstalledinaproductionlineusedforlabellingof

plasticbottles.Differentsectionsoftheconveyorsystemare

identiﬁedbyspeciﬁctechnicalnames,whicharecommonly

usedinsimilarindustrialapplication.The“singlizer”sec-

tionenablestheproducttoformintoonelanefrommultiple

lanes.The“slowdowntable”reducesthespeedofproduct

onceitexitsfromﬁller,labeller,etc.The“massﬂow”sec-

tionisusedtokeepupwithhigh-speedprocess,e.g.,ﬁller,

labeller,etc.The“transfertable”transfersthedirectionofprod-

uctﬂow.Thepurposeofthesedifferentconveyorsectionsis

thustocontroltheproductﬂowthroughdifferentprocessing

machines.

Atypicalmechanicalconveyorsystemusedinfoodandbev-

erageapplicationsconsistsofovertwohundredmechanicaland

electricalpartsdependingonthesizeofthesystem.Someof

thecommonbutessentialcomponentsthatcouldbestandard-

isedandaccumulatedintofamiliesoftheconveyorsystemare

sideframes,spacerbars,endplates,coverplates,insidebend

plates,outsidebendplates,bendtracksandshafts（drive,tailand

slave）.Thesizeandquantityofthesepartsvaryaccordingtothe

lengthofconveyorsectionsandnumberoftrackscorrespond-

ingtothewidthandtypesofchainsrequired.Theproblemsand

shortcomingsinthecurrentdesign,manufacturingandassembly

ofmechanicalconveyorsarevaried,butinclude:

4Areasofimpr

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