Standards for engineering design and manufacturing

Table of Contents Part 1 Engineering Design and Manufacturing of Discrete Products—The Scope..........................1 Chapter 1 Engineering Design and Manufacturing .........................................3 1.1 Introduction..................................................................................................3 1.2 Design Philosophy—Conventional and System Approach.........................8 1.2.1 Design Analysis .............................................................................15 1.2.2 Design for Manufacturing or Assembly .......................................17 1.2.3 Optimization in Design .................................................................18 1.2.4 The Cost Model for Design ..........................................................18 1.3 Manufacturing Philosophy—Conventional and System Approach ..........18 1.3.1 An Overview of Discrete Manufacturing Processes.....................20 1.3.2 Discrete Manufacturing Systems ..................................................21 1.3.3 Production Control ........................................................................23 1.4 Relationship between Design and Manufacturing ....................................24 1.5 Multidisciplinary Aspects of Design and Manufacturing.........................26 1.6 Use of Computers in Design and Manufacturing.....................................26 1.7 Quality and Reliability in Design and Manufacturing .............................27 1.8 Design and Manufacturing for Product Life Cycle..................................28 Bibliography........................................................................................................29 Chapter 2 Standards and Standards Organizations........................................33 2.1 Formalizing Technical Information and Procedures.................................33 2.2 Development of Standards ........................................................................33 2.2.1 A Standard for Standards—BSI Perspective ................................35 2.3 Standards-Developing Organizations ........................................................37 2.3.1 The International Organization for Standardization and Its Affiliates ............................................................................37 2.3.2 Regional Standards-Developing Organizations ............................38 2.3.3 Major National Standards-Developing Organizations ..................42 2.3.4 Professional Standards Organizations Active in Developing Standards ...............................................................44 © 2006 by Taylor & Francis Group, LLC 2.3.5 Conformity Assessment.................................................................63 2.3.5.1 Conformity Marking ......................................................64 2.3.6 Users Groups for Standards ..........................................................65 2.3.7 Commercial Organizations for the Supply of Standards..............66 2.4 Economic Benefits of Standardization—A Brief on a DIN Case Study ................................................................................68 2.4.1 Benefits for Business.....................................................................69 2.4.2 Benefits for the Economy As a Whole .........................................71 Bibliography........................................................................................................73 Chapter 3 Parametric Design and Manufacturing of Hand Tools—A Case Study......................................................79 3.1 Introduction................................................................................................79 3.2 Typical Design and Manufacture Techniques...........................................80 3.3 CAD/CAM for Hand Tools.......................................................................84 3.4 Software Selection.....................................................................................85 3.5 Parametric Modeling of Wrenches............................................................85 3.6 Conclusion .................................................................................................89 Bibliography........................................................................................................90 Part 2 Standards in Engineering Design of Discrete Products ........................91 Chapter 4 Review of Standards Related to Techniques for Engineering Design—A Product Perspective .........................93 4.1 Introduction................................................................................................93 4.2 Engineering Design Classification ............................................................93 4.3 Three-Phase Design Process .....................................................................95 4.4 Role of Product Geometry ........................................................................97 4.5 Multidisciplinary Features in Design......................................................104 4.6 Mechanical Load Analysis ......................................................................104 4.7 The Engineering Materials......................................................................112 4.8 The Machine Elements............................................................................112 4.9 The Control Element ...............................................................................114 4.10 Common Factors Related to Overall Design Process............................118 4.11 Review of Standards for Engineering Design of Discrete Products ...............................................................................120 4.12 Standards for the Design of Discrete Products......................................121 4.13 Measurement Standards..........................................................................122 © 2006 by Taylor & Francis Group, LLC 4.14 Standards Related to Materials...............................................................124 4.15 Standards for the Operation of the Product ...........................................125 4.16 Safety Standards Related to the Product................................................125 4.17 Quality Standards Related to the Product..............................................127 4.18 Reliability Standards Related to the Product .........................................129 4.19 Standards Related to Maintainability .....................................................130 4.20 Product Life Cycle and Emerging Standards.........................................133 4.21 Future Directions in the Standardization of Design Process for Discrete Products.................................................................134 Bibliography......................................................................................................135 Chapter 5 Discrete Product Development with Pertinent Standards—A Case Study ...........................................................137 5.1 System Engineering for Discrete Products .............................................137 5.2 Governing Equations and Standards .......................................................138 5.2.1 Combined Loading on the Power Screw—An Example............142 5.2.2 Coefficient of Performance—An Example .................................159 5.2.3 Engineering Properties and Standards ........................................163 5.3 Multidisciplinary Analysis for Discrete Products...................................163 5.4 Selection of Standard Components.........................................................166 Bibliography......................................................................................................166 Part 3 Standards in Manufacturing of Discrete Products ......................167 Chapter 6 Review of Standards for Manufacturing— Equipment Perspective ................................................................169 6.1 Manufacturing Processes.........................................................................169 6.2 Production Equipment.............................................................................169 6.3 Elements of Manufacturing Systems ......................................................173 6.4 Standards for Manufacturing Equipment................................................180 6.5 Standards for Design of Manufacturing Equipment...............................182 6.6 Standards Related to MMI and HCI.......................................................183 6.7 Standards Related to Operation of the Equipment .................................184 6.8 Standards Related to Measurements and Measuring Equipment Precision................................................................................192 6.9 Use of Standards in Manufacturing Operations .....................................193 6.10 Standards Related to Quality Control ....................................................199 6.11 Safety Standards Related to Use of Equipment................................... 199 © 2006 by Taylor & Francis Group, LLC 6.12 Reliability Standards Related to the Use of Equipment........................203 6.13 Maintainability Standards Related to Use of Equipment ......................211 6.14 Waste-Disposal Standards ......................................................................213 6.15 Equipment Life Cycle Standard .............................................................214 6.16 Standards Related to Information Transfer ............................................220 6.17 Standards Related to Material-Handling Equipment .............................220 6.18 Future Directions in the Standardization of Manufacturing Equipment .................................................................222 Bibliography......................................................................................................226 Chapter 7 Process Planning for a Revolute Robot Using Pertinent Standards—A Case Study ...........................................................229 7.1 Process Planning......................................................................................229 7.2 Manufacturing Facilities and Available Resources.................................230 7.3 Use of Standards in Process Planning ....................................................230 7.4 Process Planning for a Revolute Robot ..................................................230 7.4.1 Process Planning for Parts in Subassemblies .............................231 7.4.2 Process Planning for the Subassemblies.....................................232 7.4.3 Process Planning for the Robot Assembly..................................232 Bibliography......................................................................................................332 Part 4 Standards for the Use of Discrete Products ........335 Chapter 8 Review of Standards Related to the Usage of Discrete Product—A User’s Perspective................................337 8.1 Introduction..............................................................................................337 8.2 Standards Related to Man-Machine Interface in Discrete Products ................................................................................338 8.3 Standards Related to Human-Computer Interaction in Discrete Products ................................................................................338 8.4 Standards Related to Ergonomics of Discrete Products.........................338 8.5 Standards Related to Output from the Discrete Products ......................346 Bibliography......................................................................................................359 Chapter 9 Application of Human Factors to Design and Manufacturing of Discrete Products—A Case Study.................361 9.1 Introduction..............................................................................................361 9.2 Capabilities and Limitations of Users.....................................................362 9.2.1 The Auditory Modality................................................................362 © 2006 by Taylor & Francis Group, LLC 9.2.2 The Visual Modality....................................................................362 9.2.3 Other Sensory Limitations ..........................................................362 9.3 Information-Processing Limitations........................................................362 9.3.1 Expectations.................................................................................362 9.3.2 Information Processing................................................................362 9.3.3 Emotionalism...............................................................................363 9.3.4 Boredom ......................................................................................363 9.3.5 Sensitivity to Stress .....................................................................363 9.4 Limitations of an Effector Subsystem ....................................................363 9.4.1 Body Measurement, or Anthropometry ......................................363 9.4.2 Lifting and Force Capabilities.....................................................363 9.4.3 Response-Speed Capability .........................................................363 9.4.4 Tracking Capabilities...................................................................363 9.5 Human Performance Criteria ..................................................................364 9.5.1 Workplace Design Criteria ..........................................................365 9.5.2 Human Performance Assessment Criteria ..................................365 9.6 The Availability and Application of Standard Information ....................365 Bibliography......................................................................................................369 Part 5 Support Standards in Design and Manufacturing of Discrete Products ......................371 Chapter 10 Review of Support Standards for Discrete Products ................373 10.1 Automation in Discrete Products ...........................................................373 10.1.1 Information Representation, Coding, and Exchange Standards............................................................374 10.1.2 Interface Hardware Standards....................................................374 10.1.3 Standards Related to Sensors, Transducers, and Actuators .............................................................................374 10.1.4 Data Communication Standards ................................................377 10.1.5 Standards Related to Programming Languages ........................381 10.1.6 Software-Development Standards..............................................381 10.2 Quality Assurance...................................................................................381 10.2.1 Quality-Assurance Standards.....................................................382 10.3 Environmental Considerations................................................................386 10.3.1 Standards Related to Disassembly, Recycling, and Disposal...............................................................................386 10.3.2 Standards Related to Environmental Impact.............................388 10.4 e-Business Related Standards.................................................................390 Bibliography......................................................................................................391 © 2006 by Taylor & Francis Group, LLC Chapter 11 Digital Interfacing and Control Software Development— A Case Study ..............................................................................393 11.1 Microprocessor Interfacing for Discrete Products .................................393 11.2 Interface Circuit Design .........................................................................394 11.3 Control Software Design ........................................................................395 11.3.1 Use of Application-Specific Standard for the Development of Control Software.................................395 11.4 Microprocessor Interfacing for a Computerized Numerical Control Milling Machine ......................................................396 11.4.1 Design of Printed Circuit Boards for Implementation of Computerized Numerical Control at a Milling Machine ............................................................... 398 11.4.2 Software Modules for a Computerized Numerical Control Milling Machine ...........................................................398 11.4.3 Use of Standards in Developing Control Software and Hardware for Computerized Numerical Control Milling Machine ........................................................................498 Bibliography......................................................................................................499 Appendix ..........................................................................................................501 A1 Digital Catalogs for Standard Mechanical Components ........................501 A2 Digital Catalogs for Standard Machine Elements ..................................501 A3 Digital Catalogs for Standard Control Elements ....................................501 A4 Digital Catalogs for Engineering Materials............................................501 A5 Digital Libraries for Standards................................................................502 A6 Digital Websites Related to Standards....................................................502