A novel concept of Bowden cables flexible and full-automated manufacturing process improving quality and productivity

Martins, Nuno; Silva, F.J.G.; Campilho, R.D.S.G.; Ferreira, Luı́s Pinto

doi:10.1016/j.promfg.2020.10.062

Cited by 9 publications

(8 citation statements)

References 13 publications

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“…ZHPIM are characterized as high-pressure die casting injection machines having as main function the injection of Zamak 5 on a steel cable end. Many studies have been performed around Bowden cables [40][41][42], since the study of wire rope corrosion until the manufacturing process optimization. Depending on the figure dimen-sion and operator ability, these machines may produce up to 600 to 900 cables per hour.…”

Section: Manufacturing Process Characterizationmentioning

confidence: 99%

Case-based product development of a high-pressure die casting injection subset using design science research

Tojal¹,

Silva²,

Campilho³

et al. 2022

FME Transactions

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High pressure die casting is widely used in metalworking industry. Many of the components and devices directly linked to the hot parts are subjected to severe wear. However, some design updates can enlarge the lifespan of these components and devices. This paper proposes to show how a sustainable maintenance can be obtained by focusing resources on the analysis of the critical problem and its consequent mitigation, whereas they are originated on the human, machine/process or supplier level. Design science research (DSR) was the iterative research methodology chosen to integrate this work. The completion of the objective with the implementation of this new injection subset concept brought extremely beneficial results, such as reduction of its consumption, reduction of acquisition cost and waste generated, and reduction of the intervention time during maintenance operations, as well as increase in equipment availability time.

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Section: Manufacturing Process Characterizationmentioning

confidence: 99%

Case-based product development of a high-pressure die casting injection subset using design science research

Tojal¹,

Silva²,

Campilho³

et al. 2022

FME Transactions

Self Cite

View full text Add to dashboard Cite

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“…This concept can be easily integrated into the industry 4.0 philosophy, linking it to other engaging equipment and the production management system. Martins et al [13] also worked on the development of a new equipment concept for the manufacture of automotive Bowden cables. This new concept allowed them to improve the product and productivity, reducing cycle times by 25%.Santos et al [14] devoted their attention to how Bowden cables are transported over equipment in some integrated operations.…”

Section: Literature Reviewmentioning

confidence: 99%

Investigations on the oxidation of Zn-coated steel cables

Pinto¹,

Silva²,

Baptista³

et al. 2021

FME Transactions

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The automotive component industry has been constantly being studying to improve its performance. Bowden cables are present in opening doors, moving windows and others. In braided cables formed by galvanized wires with Zn steel exposed to the usual environmental conditions, the generation of ZnO appears, a phenomenon known as "white corrosion". The investigation consisted of mitigating the causes of the ZnO formation. Scanning electron microscopy (SEM) and Electron Probe Micro-Analyzer (EPMA) technology, allowed to detect that the generation of ZnO was induced by the presence of nucleating elements of ZnO on the surface of the steel cable before galvanizing with Zn. The S, Cl and O became visible in the interface between coating and substrate. This allowed concluding, under the coating, there were harmful products capable of triggering the ZnO nucleation reaction. So, the storage and cleaning of the steel wire before galvanizing is essential to prevent the ZnO formation.

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“…Depending on the application, the inner cable may be subject to other operations prior to its assembly into the control cable set. An automated manufacturing cell was developed by Martins et al [16], in which the inner cable was prepared for the zamak injection of its terminals and subsequently injected. In addition, the cable was cut-to-length and strength-tested.…”

Section: Introductionmentioning

confidence: 99%

“…Although the work reported by Moreira et al [13] is related to control cables, its focus was on the integration within a manufacturing cell, and, thus, the individual production steps were not fully described or addressed. Similarly, Martins et al [16] described the overall process and the important steps, but the detail of the cutting process was omitted.…”

Section: Introductionmentioning

confidence: 99%

Design of a Spiral Double-Cutting Machine for an Automotive Bowden Cable Assembly Line

et al. 2022

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The manufacture of automotive components requires innovative technologies and equipment. Due to the competitiveness in the sector, the implementation of automatic and robotic equipment has been vital in its development to produce the largest number of products in the shortest amount of time. Automation leads to a significant reduction in defects and enables mass production and standardization of the final product. This work was based on the need of an automotive components’ company to increase the rate of spiral cable cutting, used as protection for Bowden (control) cables. Currently, this component, used in automotive systems, is processed with simple cutting machines and cleaning machines. Based on the design science research (DSR) methodology, this work aims to develop a machine capable of performing the cutting and cleaning of two spiral cables simultaneously and automatically. The development of this machine was based on existing machines, and the biggest challenge was the implementation of a double-cutting system. The designed machine met the initial requirements, such as enabling the simultaneous cut of two spirals, being fully automatic, doubling the output over the current solution, and fully complying with the current legislation.

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A novel concept of Bowden cables flexible and full-automated manufacturing process improving quality and productivity

Cited by 9 publications

References 13 publications

Case-based product development of a high-pressure die casting injection subset using design science research

Case-based product development of a high-pressure die casting injection subset using design science research

Investigations on the oxidation of Zn-coated steel cables

Design of a Spiral Double-Cutting Machine for an Automotive Bowden Cable Assembly Line

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