Designing a Novel System for the Introduction of Lubricant in Control Cables for the Automotive Industry

Ribeiro, Rodrigo Borges; Silva, Francisco; Pinto, A. M. G.; Campilho, R.D.S.G.; Pinto, Helder

doi:10.1016/j.promfg.2020.01.096

Cited by 10 publications

(6 citation statements)

References 20 publications

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“…The Bowden cables can cross damp areas in vehicles, so there are associated risks of corrosion and the most models are filled with grease in the part covered by the outer spiral. The filling process of this grease also presented some problems, which were properly studied by Ribeiro et al [20]. Indeed, significant waste of that grease was recorded in the reservoirs used for its storage immediately before injection.…”

Section: Literature Reviewmentioning

confidence: 93%

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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Section: Literature Reviewmentioning

confidence: 93%

Investigations on the oxidation of Zn-coated steel cables

Pinto¹,

Silva²,

Baptista³

et al. 2021

FME Transactions

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“…The quality of the metallic cable that underlies the effect produced by Bowden cables (power transmission through complex layouts) was also studied by Pinto et al [35], verifying that the storage conditions of this cable are critical for the preservation of the proper functioning of these components inside the automobile. Precisely to eliminate corrosion problems in operation, with the respective consequences for the force that the user needs to exert to perform a certain action, Ribeiro et al [36] developed an integrated grease injection system between the wire rope and the spiral tube, which aimed to significantly improve productivity, namely via the ergonomics of the workers in this function, ensuring a reduction in grease waste as well, thus increasing the economic and environmental sustainability of the process [37]. The Zamak terminals injected at the ends of the metallic cable, where the force is in fact exerted, are equally important, since this process involves the injection of a light alloy, in a very small amount, with a very high speed, and it requires that the complete filling of the mold is achieved.…”

Section: State Of the Artmentioning

confidence: 99%

“…This At the injection machine level, the main idea is to use the equipment typically used (Figure 15). The main reason was the cost, as the latest versions of these machines cost more than EUR 20,000, and it is possible to restore and upgrade existing machines for a small fraction of this price, thus contributing to the reuse of equipment, avoiding their landfilling and the respective environmental consequences [36,65]. This sub-equipment was placed on rails, in order to facilitate access to its components for maintenance purposes.…”

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confidence: 99%

A Novel Fully Automatic Concept to Produce First Subset of Bowden Cables, Improving Productivity, Flexibility, and Safety

Eiras,

Silva,

Campilho

et al. 2023

Machines

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With a view to maintaining the competitiveness required by the market, the automotive industry strongly encourages its suppliers to develop new production methods and technologies capable of reducing the costs of produced products, ensuring the necessary quality, and increasing flexibility, with a view to responding more easily to the customization of the products that the market increasingly demands. The main goal of this work was to increase the flexibility and productivity of equipment capable of producing the first subset that constitutes the product commonly known as the Bowden cable. To this end, the design science research methodology was used, which was understood as the most effective in describing scientific work related to the improvement of existing systems. Bowden cables are cables that activate various devices in the car, such as opening doors, moving window glasses, and adjusting some car seats, among others. The work consisted of integrating several operations usually carried out for the manufacture of the referred subset, reducing logistics operations and manual work, increasing operator safety, and increasing the production rate and flexibility of the equipment, by reducing the setup time. For this purpose, new mechanical concepts were developed, and automation was applied, which resulted in a completely new concept, able to fulfill all the objectives initially set. It should be noted here that the new equipment allowed a production rate of 1140 p/h, when the initial objective was 1100 p/h; it requires an investment of only around EUR 55,000 (easy return on investment), occupies only 11.6 m2, and has reinforced safety systems to avoid workers’ injuries, an aspect that is very important in this type of equipment, where operators deal with cutting systems and high temperatures. The dissemination of this concept could help other researchers to easily find solutions to certain problems that they face in the development of modern equipment. The main contributions of this paper are the novel concepts created to overcome some process difficulties, which can be used for a wide range of other processing situations with similar difficulties. The solutions proposed allow a decrease in the cycle time, present high flexibility, save workshop space, and are affordable in terms of global cost.

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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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Designing a Novel System for the Introduction of Lubricant in Control Cables for the Automotive Industry

Cited by 10 publications

References 20 publications

Investigations on the oxidation of Zn-coated steel cables

Investigations on the oxidation of Zn-coated steel cables

A Novel Fully Automatic Concept to Produce First Subset of Bowden Cables, Improving Productivity, Flexibility, and Safety

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

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