Automotive Engineering - May 2019 - 12
TECHNOLOGY REPORT
MATERIALS
For bonding dissimilar
materials, adhesives
can be a sticking
point-or lack of it
floor. The Ford Automation Software
Template (FAST) was initiated in 2010,
a standardization targeting traceability
and configurability at the assemblytool level.
Today, Ford's manufacturing controls
specification is comprised of an 800page sourcebook "ruled with an iron fist"
Bastian said, and applied to both inhouse and supplier systems. One element of the global specification includes
virtual RFID (a system designed, owned
and maintained by Ford's software
team) using camera-based monitoring
to track millions of parts in real time.
Another element has standardized
Ford-patented condition-monitoring on
more than 4,000 CNC machines deployed in manufacturing facilities globally.
Ford's current digital toolset of more
than 40 programs assist in everything
from throughput simulators that permit
the plant itself to be right-sized, to inplant 3D scanning that improves layout
and dimensioning. Virtual-reality tools
recreate assembly sequences and assess dunnage locations, and 3D process
simulations model everything from
work-path reaches to finger clearances.
"As PD is going through and releasing design updates, they come to us
instantaneously and we can quickly determine whether or not a design change
is going to impact a manufacturing system we're in the process of building,"
Bastian explained.
12 May 2019
Flagship digital manufacturing
space
The LTP facility features over 2 million ft2
of manufacturing space, employs 2,500
people and produced over 1.5 million 6-,
8- and 10-speed automatic transmissions last year, with that production figure expected to climb 25% in 2019. The
production line for the 10R transmission
will see 19 different variants being produced each day for products such as the
Ranger, F-150, Mustang and Explorer.
Over 900 cameras on the 10R and 8F
palletized, asynchronous assembly lines
capture more than 3,000 features during production. This generates a rich
"birth history" of each transmission accessed via its unique 2D matrix identifier, (think QR code) linking to data
about each part and subsystem, each
tool used and that tool's condition and
performance when applied to that specific component.
"We get information from our suppliers of valve-body parts, and take that
data set and marry it with a data set that
we collect," Bastian said. "For every transmission, we broadcast that information to
the vehicle plants around the world,
which have the capability to enable that
level of characterization. That transmission is personalized based off of the design of that control system. With the data
we're collecting, you get the best-possible shift capability, out of the gate."
Paul Seredynski
When production volume is upscaled, the
chosen adhesive can be less than optimal.
AUTOMOTIVE ENGINEERING
FROM TOP: FORD; INTERTRONICS
Ford's digital manufacturing footprint includes a host of globally networked computer numeric
control (CNC) metal cutting machining centers.
As the auto industry adopts an increasingly wide mix of materials in its pursuit
of constantly tougher weight-saving
and service-longevity targets, joining
mixed materials using precisely-compatible adhesives is a crucial aspect of
the formula. Considering the expanding
role of adhesives in the mixed-materials
matrix, a new warning to design engineers comes from Peter Swanson,
Managing Director of adhesives specialist Intertronics, of the need to fully appreciate through-life performance.
"Adhesives are commonly specified
during product development, often based
on functional requirements," he said. "But
when production is upscaled, the chosen
adhesive can be less than optimal; application and curing may be difficult, unreliable, challenging to automate and demand too much time. Intended production quantities for a product should always influence adhesive choice.
"In an ideal world, all surfaces would be
bonded by one perfect adhesive,"
Swanson continued. "But a single adhesive that can cure on demand, operate at
any temperature, resist all solvents, that
sticks to everything and is completely and
instantly workable-is an impossibility!
Automotive Engineering - May 2019
Table of Contents for the Digital Edition of Automotive Engineering - May 2019
Automotive Engineering - May 2019
Contents
Editorial: Choking on the haze of California vs. the Feds
SAE Standards News
Supplier Eye
What We’re Driving
Technology Report
Road Ready
New platform, chic sheetmetal for tech-centric 2020 Range Rover Evoque
Lightweighting 2019
F1 streamlines for closer racing
Unlocking DfAM’s potential
Product Briefs
Reader Feedback
Companies Mentioned, Upcoming, Ad Index
Q&A
Automotive Engineering - May 2019 - Intro
Automotive Engineering - May 2019 - Automotive Engineering - May 2019
Automotive Engineering - May 2019 - Cover2
Automotive Engineering - May 2019 - Contents
Automotive Engineering - May 2019 - Editorial: Choking on the haze of California vs. the Feds
Automotive Engineering - May 2019 - 3
Automotive Engineering - May 2019 - SAE Standards News
Automotive Engineering - May 2019 - Supplier Eye
Automotive Engineering - May 2019 - What We’re Driving
Automotive Engineering - May 2019 - 7
Automotive Engineering - May 2019 - Technology Report
Automotive Engineering - May 2019 - 9
Automotive Engineering - May 2019 - 10
Automotive Engineering - May 2019 - 11
Automotive Engineering - May 2019 - 12
Automotive Engineering - May 2019 - 13
Automotive Engineering - May 2019 - Road Ready
Automotive Engineering - May 2019 - 15
Automotive Engineering - May 2019 - New platform, chic sheetmetal for tech-centric 2020 Range Rover Evoque
Automotive Engineering - May 2019 - 17
Automotive Engineering - May 2019 - Lightweighting 2019
Automotive Engineering - May 2019 - 19
Automotive Engineering - May 2019 - 20
Automotive Engineering - May 2019 - 21
Automotive Engineering - May 2019 - 22
Automotive Engineering - May 2019 - 23
Automotive Engineering - May 2019 - 24
Automotive Engineering - May 2019 - 25
Automotive Engineering - May 2019 - F1 streamlines for closer racing
Automotive Engineering - May 2019 - 27
Automotive Engineering - May 2019 - 28
Automotive Engineering - May 2019 - 29
Automotive Engineering - May 2019 - Unlocking DfAM’s potential
Automotive Engineering - May 2019 - 31
Automotive Engineering - May 2019 - 32
Automotive Engineering - May 2019 - 33
Automotive Engineering - May 2019 - Product Briefs
Automotive Engineering - May 2019 - 35
Automotive Engineering - May 2019 - 36
Automotive Engineering - May 2019 - 37
Automotive Engineering - May 2019 - Reader Feedback
Automotive Engineering - May 2019 - Companies Mentioned, Upcoming, Ad Index
Automotive Engineering - May 2019 - Q&A
Automotive Engineering - May 2019 - Cover3
Automotive Engineering - May 2019 - Cover4
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