Modern English Training for Engineers (Ebook): Englisch für die Aus- und Weiterbildung von Ingenieuren.

By KARLHEINZ ZUERL

Englisch für die Aus- und Weiterbildung von Ingenieuren.
47 zukunftsorientierte Einsatzgebiete der Computertechnologien in der Industrie.
Mit 127 Bildern, einem Grammatikteil, einem Übungsteil mit Antworten sowie Wörterbuchteilen Englisch-Deutsch und Deutsch-Englisch

• Language: English
• Publisher: Karl-Heinz Zürl
• Release date: Mar 30, 2017
• ISBN: 9783939366140

KARLHEINZ ZUERL

Karlheinz ZUERL leitete verschiedene internationale Projekte bei BMW, General Motors, Valeo und Bosch. Seit über 20 Jahren berät, trainiert und unterstützt er Unternehmen bei deren Qualitätsicherungs-, Einkaufs- und Verhandlungsaktivitäten, hauptsächlich in den Bereichen Automobilbau, Maschinenbau, Elektrik, Elektronik. Zahlreiche Veröffentlichungen in Deutsch und Englisch.

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ANNOTATIONS

Glossary of Acronyms

Industrial Training

1 Library of CAD/​CAM Parts

Aufbau einer Normteilbibliothek

General

If data are stored in such a way as to permit online access, storage is called a database. Databases consist of ¹ a collection of information from a specific field of knowledge. They may either consist of physical files directly accessed by programs or a logically accessible data collection administered by a database management system (see „Software Verification and Validation" by M.S. Deutsch, Prentice Hall Inc., USA).

Advantages:

linking of several databases to a central database is possible.

it is possible for several users to have access to the database, if safety regulations ² permit.

a database prevents employees ³ from storing data as private files ⁴ which are not available to other users.

in the case of repetitive ⁵ design elements ⁶ , it is important that an updated, valid ⁷ common database is accessible to all users.

Disadvantages:

stored information has to be continuously updated.

Types of fields: ⁸

A database contains ⁹ structured information, so-called records ¹⁰ , which consist of several fields. Several types of fields can be defined within one field, e.g.

fields for characters ¹¹ ( numbers ¹² , letters ¹³ , symbols ¹⁴ , spaces ¹⁵ )

fields for dates

logical fields ¹⁶ (1 or 0, Y or N, T for true or F for false)

memo fields (for texts, charts ¹⁷ , calculations ¹⁸ , or others)

numerical fields ¹⁹ (numbers only).

Types of databases ²⁰

In order to access data easily databases have to be connected with each other. Nowadays a variety of ²¹ database technologies is available to handle complex data connections ²² .

Hierarchical databases (tree structure); see Figure 1.1

Usage ²³ : For relationships where a number of lower categories (or sub-sectors) are derived ²⁴ from a generic term ²⁵ (sequential data storage).

Disadvantages: Relationships ²⁶ between data cannot be described ²⁷ .

Figure 1.1

Network database (see Figure 1.2)

Usage: Where much information has to be interconnected. Advantage: Relationships between data are possible in all directions.

Disadvantages:

Complex structure, storage is not easy

Before inputting data ²⁸ , the person responsible for the database has to inform ²⁹ the computer of the structure of the data and all the possible ways of access ³⁰ (a specialist is required ³¹ ).

Figure 1.2

Related database ³² (see Figure 1.3)

Figure 1.3

Special feature ³³ : Files are stored independently of each other (index-sequential files) in the form of charts. The columns ³⁴ are called domains (fields), the sum of all columns is called relations, the rows ³⁵ are called „records". The key concept ³⁶ represents ³⁷ the search criterion ³⁸ . Several charts are connected using this concept (see Figure 1.4).

Figure 1.4

Advantages of the relational database:

more flexibility, as defined access paths are not necessary

can be used without programming knowledge

Disadvantages:

to answer inquiries a computer has to search through ³⁹ the complete set of entries ⁴⁰ in all the charts.

with complex concepts ⁴¹ a relatively long access time is needed.

Field of applications

One example within the wide range of applications is:

Library for Tool Design ⁴²

When the library is called up on the screen ⁴³ by the tool designer ⁴⁴ or production equipment planner ⁴⁵ , a menu ⁴⁶ is given. The menu is divided into several search images ⁴⁷ (see Figure 1.5).

The standard part library is divided into sections for screws ⁴⁸ , pins ⁴⁹ , nuts ⁵⁰ , locking parts ⁵¹ , etc. If you enter screws, you will get Figure 1.6, to enable you to choose between fillister head cap screws ⁵² , hexagon head screws ⁵³ , countersunk screws ⁵⁴ , or others.

Figure 1.5

Figure 1.6

The design base library is divided into material and symbol lists ⁵⁵ , lists of shape position tolerances ⁵⁶ and formats ⁵⁷ , treatment symbols ⁵⁸ and wiring diagrams ⁵⁹ , design information for the punching department ⁶⁰ , pressroom ⁶¹ , chassis ⁶² and assembly ⁶³ sections.

The parts purchase library lists information on system components ⁶⁴ from different suppliers. The choice of component will depend on its price ⁶⁵ and measurements ⁶⁶ . For example, if aluminium mould sets ⁶⁷ and accessories ⁶⁸ are required, one can choose from several parts with different dimensions (see Figures 1.7 and 1.8).

Figure 1.7

Figure 1.8

The range of products for mould sets contains, for example, locating rings ⁶⁹ protective caps ⁷⁰ , screws, mould clamping plates (with nozzle or ejector sides) ⁷¹ , cast-on bushings ⁷² , guide pillars ⁷³ , guide bushings ⁷⁴ , ejector plates ⁷⁵ , guide flanges ⁷⁶ , ejector bolts ⁷⁷ , clamping and stripper plates ⁷⁸ .

Sufficient knowledge of tooling and of the material characteristics ⁷⁹ and composition ⁸⁰ of the aluminium alloy ⁸¹ is required to make the best choice.

2 Stackability of Car Parts

Kostenreduzierung durch verbessertes Stapeln

General

It is currently impossible for a designer to test ⁸² how parts behave ⁸³ during stacking and transportation (see Figure 2.1), by using a CAD system. The following introduces a project to enable the CAD part designer to investigate the stackability ⁸⁴ of car body parts ⁸⁵ with the help of the CAD system. Its aim ⁸⁶ is to improve the stackability of parts in transportation racks and to explore ⁸⁷ the possibilities of cutting costs ⁸⁸ .

Figure 2.1

Development and production of transportation racks are carried out independently of ⁸⁹ the single component ⁹⁰ design and only ⁹¹ after the production of prototype parts.

Moreover ⁹² , the costs of racks and of the transportation of parts are rising due to the increasing shipment ⁹³ of components ⁹⁴ to assembly plants ⁹⁵ situated all over the world.

Every European car manufacturer ⁹⁶ owns ⁹⁷ approx. two million transportation racks; the majority are expensive, specialized racks ⁹⁸ . Visitors to Japanese car factories, however, have discovered very few specialized racks. The reason is that the optimizing stacking process has already been completed there.

Field of applications

Car manufacturers have several press and assembly plants around the world. For the distribution ⁹⁹ of car parts, the plants hire ¹⁰⁰ railway wagons ¹⁰¹ , airplanes, lorries or ships. The parts are stored in standard and specialized racks.

Outer parts ¹⁰² are transported separately, suitably spaced from each other. The inner parts ¹⁰³ , e.g. door reinforcements ¹⁰⁴ , are mostly ¹⁰⁵ stacked together with gaps between them which are determined by bent ¹⁰⁶ joints ¹⁰⁷ or rabbets ¹⁰⁸ on their sides ¹⁰⁹ . They are not allowed to touch ¹¹⁰ in order to avoid damage. Unsuitable transportation methods can result in unusable parts causing great financial loss.

Advantages

This program ¹¹¹ can only ¹¹² be useful ¹¹³ if applied at a very early design stage ¹¹⁴ when no stacks have been planned or produced. Its advantage is that it designs parts which meet the requirements for proper transport ¹¹⁵ , e.g. with similarly ¹¹⁶ inclined surfaces ¹¹⁷ . If a slight modification of design facilitates ¹¹⁸ closer ¹¹⁹ stacking and more parts can be placed in each rack, fewer railway wagons will be needed and a noticeable reduction of costs will be achieved.

Stages of a project: ¹²⁰

First of all the economic feasibility ¹²¹ has to be studied, and then the practicability of the current CAD system tested. After that the new software requirements, their practicality and finally the menu shells have to be agreed with the CAD designers. In the final stage, a prototype is developed in the CAD system and the new software is tested and implemented; staff are trained to use it, and then it is published ¹²² for sale or publicity ¹²³ purposes.

Economy

The program for stackability of body parts works on the principle of using duplicated parts ¹²⁴ , which are made to collide ¹²⁵ in a simulation process, in order to recognize ¹²⁶ and eliminate ¹²⁷ points of impact ¹²⁸ . Therefore, the prerequisite for optimum economy is a complete description of CAD models with surfaces shown (see Figure 2.2).

Figure 2.2

An example of the use of cost-efficiency calculation ¹²⁹ to support project implementation ¹³⁰ :

A project leader reports:

"We will develop this software for workstations instead of mainframes ¹³¹ . This will reduce the high investment and carriage costs. The rack development to improve utilization of racks and reduce the number of specialized racks will be to our advantage. For example, outer panel parts for about 10,000 cars need to be transported from Spain to London annually. There are about 20 parts per wagon which costs us about £200, i.e., one part costs us about £10. If a car needs two specific parts, then you have a transport cost of £200,000 per year. Even if we merely reduce the space for parts per rack by 10   %, we would save £20,000 for one critical part."

3 Initiation and Development of Computer Aided Design

Einstieg und Umstieg

Planning basis ¹³² of CAD/​CAM

Switching from manual to Computer Aided Design, or from one CAD system to another, can be very frustrating. Mistakes in planning can negate the potential advantages.

1. Planning aids ¹³³ to facilitate introduction ¹³⁴ or switching ¹³⁵ of systems

No segmentation ¹³⁶ of the organization

Technical sections are very often responsible for CAD, whereas ¹³⁷ commercial DP (data processing) ¹³⁸ is located in the financial accounts section ¹³⁹ or the material management section ¹⁴⁰ . There is a partial overlap ¹⁴¹ of tasks (e.g. materials management, the optimization of flow organization ¹⁴² , CAD/ production planning and control system ¹⁴³ coupling ¹⁴⁴ ) in both DP organizations.

NB ¹⁴⁵ : synergy effects ¹⁴⁶ reduce ¹⁴⁷ enterprise expenses ¹⁴⁸ .

Management must participate in the action

Management has to set targets, e.g. to achieve a 10 % increase in productivity within the design departments, otherwise CAD technology will remain an area only for handicraft enthusiasts ¹⁴⁹ and experts.

The aim is to motivate design department managers to inspire ¹⁵⁰ a CAD pioneering spirit ¹⁵¹ in designers with drawing board ¹⁵² experience, to make profitability calculations ¹⁵³ , to train employees ¹⁵⁴ , etc.

Selection of systems should not only be seen from the technical point of view

Buyers should obtain the last two or three company reports ¹⁵⁵ from the seller to use as a basis for decisions. CAD is a strategic investment ¹⁵⁶ . Therefore it is necessary to have a financially strong and reliable partner.

Do not place CAD in the foreground ¹⁵⁷

The most cost effective design is the one which does not exist, e.g. because a similar ¹⁵⁸ , functional part is already doing the task.

Proliferation ¹⁵⁹ of unnecessary parts is prevented ¹⁶⁰ by classifying parts in accordance with ¹⁶¹ DIN 4000 and having a standards department ¹⁶² specializing in these tasks.

Development of a concept

It is well known that CAD data is useful in design but it is imperative ¹⁶³ for manufacturing ¹⁶⁴ and assembly ¹⁶⁵ . Nevertheless many people complain ¹⁶⁶ about interface problems ¹⁶⁷ and incompatible ¹⁶⁸ DP components.

Therefore, it is necessary to introduce ¹⁶⁹ the framework ¹⁷⁰ of the CAD conceptual stage ¹⁷¹ as early as possible. The actual and planning state of all neighbouring ¹⁷² DP project plans should be taken into consideration ¹⁷³ . Those who disregard ¹⁷⁴ this may later be confronted with ¹⁷⁵ expensive interface adjustments ¹⁷⁶ .

2. What a CAD system should include

The systems have developed from a two-dimensional drawing system ¹⁷⁷ into a three-dimensional design package ¹⁷⁸ . Most systems work with solid models ¹⁷⁹ , but some use wire frame ¹⁸⁰ or surface models ¹⁸¹ . Graphic data has to be distributed to external CAD systems. The Autocad-interface DXF, the German VDAFS and the American IGES interfaces ¹⁸² have developed into the most important data exchange formats. ¹⁸³

User functions ¹⁸⁴ :

User functions should be clearly structured ¹⁸⁵ and have a dynamic screen layout ¹⁸⁶ , consisting of the menu field ¹⁸⁷ , the text input ¹⁸⁸ and the indicator field ¹⁸⁹ , as well as a sufficiently ¹⁹⁰ large drawing area ¹⁹¹ , with self-explanatory ¹⁹² menu structure ¹⁹³ , complete iconism ¹⁹⁴ and additional ¹⁹⁵ aiding texts. The meaning ¹⁹⁶ of symbols and icons must be clear.

3. Suggestions for a successful entry ¹⁹⁷

Training sessions (workshops) should be organized giving both the know-how and the opportunity to design with different kinds of software which will enable users to make the correct choice ¹⁹⁸ of CAD systems. Coupling concepts between the Computer Aided Design (CAD), production planning and control systems (PPS) and the work planning department ¹⁹⁹ (NC programming), plus the use of interfaces ²⁰⁰ , should be included in this training package ²⁰¹ .

4. Qualification of employees

An effective employee training course is essential for the acceptance of the program. A CAD project is doomed to failure ²⁰² without motivated users.

Field of application

CAD is currently ²⁰³ used in 32   % of all fields of work ²⁰⁴ . 70   % of all users use personal computers (PCs) as hardware, 24   % work at workstations and 3   % work with mainframes (host computers). The differences between workstation and PC will become indistinct ²⁰⁵ ( declaration of values ²⁰⁶ , stated in ²⁰⁷ 1996)

Economy

1. Costs ²⁰⁸ :

It is important to ensure that investment ²⁰⁹ in design areas is viable ²¹⁰ and measurable ²¹¹ by comparing ²¹² the actual status ²¹³ with the target figures ²¹⁴ .

The degree of success cannot be proven ²¹⁵ later.

A careful and thorough ²¹⁶ preparation phase ²¹⁷ for system selection and introduction pays early dividends by:

getting to know the state of the art ²¹⁸

determining own needs ²¹⁹ , desires ²²⁰ and requirements ²²¹ , including the company's future perspectives ²²²

creating an unambiguous ²²³ list of requirements ²²⁴

To a considerable extent ²²⁵ the cost-effectiveness of CAD systems is dependent on ²²⁶ structured ²²⁷ and clearly laid out ²²⁸ user screens ²²⁹ . Investigation has shown that only a small number of the different functions within a CAD system are used frequently ²³⁰ .

It is estimated ²³¹ that approx. 15   % of acquisition costs per year should be allowed for training and retraining ²³² of CAD designers as well as ²³³ upgrading ²³⁴ CAD systems.

Designers without any DP knowledge have difficulties ²³⁵ during CAD training. It is recommended that they acquire DP knowledge before using CAD equipment.

2. Profit ²³⁶

Increase of productivity with CAD (see Figure 3.1). Working with alternatives has shown that efficiency rises ²³⁷ by 250   % within 1 1/​2 years.

Figure 3.1

4 Vehicle Safety

Sicherheit durch Computersimulation

General

CAD applications, transferring ²³⁸ CAD-data to tooling machines ²³⁹ and computer simulation effectively reduce engineering leadtime ²⁴⁰ . Simulation covers strength ²⁴¹ and rigidity ²⁴² analysis, as well as the behaviour ²⁴³ of vehicles during collisions.

Car manufacturers ensure vehicle safety by improving steering wheels, seat belts, seat strength, driver and passenger leg impact areas, head restraints ²⁴⁴ , side impact protection, fuel systems, airbags and front-end designs for pedestrian protection. The crash tests carried out by the German automobile magazine, Automotor-Sport, have undoubtedly influenced the tests carried out by the manufacturers themselves.

Computer modelling and analysis are both faster and simpler than arranging a series of crash tests.

Applications of on-screen computer modelling and analysis

Steering wheel ²⁴⁵ design

It has been proposed that a law requiring safer steering wheels to be fitted ²⁴⁶ should be introduced as quickly as possible . The performance of different steering wheels in head-impact tests shows the huge variation between different designs and significant ²⁴⁷ scope ²⁴⁸ for improvement.

Restraint systems ²⁴⁹ / Seat belt ²⁵⁰

With the improvement in face ²⁵¹ and chest ²⁵² protection achieved by restraint systems, suggestions have been made that further research is needed in other areas, such as the lower leg area.

Current legislation is not adequate, because it is based on research where the test dummy used is one sized, placed in a specified position and not clothed; and the realistic adjustments ²⁵³ of seat belts are not used.

Seat design

The relevant laws do not take into account ²⁵⁴ the existence of rear-seat passengers. Front-seat occupants can suffer spinal injuries ²⁵⁵ from the knees of rear-seat passengers.

Side impact

Most manufacturers meet current requirements by introducing a beam ²⁵⁶ , which spans the width of the door. In accidents such as side-swiping ²⁵⁷ a lamp post ²⁵⁸ , or side impact by a motorcycle, a beam of this sort can provide useful protection for passengers. The European side impact crash test barrier ²⁵⁹ is a rigid ²⁶⁰ frame with a deformable impact surface that is at right angles ²⁶¹ to the direction of travel.

Side airbags

The side-airbag system from Volvo, called SIPSBAG, has a sensor, nonelectrical connection and bag, all mounted in