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Automation of the industrial transformer core assembly process is highly desirable. A survey undertaken by the author however, revealed that due to the high cost of existing fully automated systems, Australian manufacturers producing low to medium transformer volumes continue to maintain a manual construction approach. The conceptual design of a cost-effective automation system for core assembly from pre-cut lamination stacks was consequently undertaken. The major hurdle for automating the existing manual process was identified as the difficulty in reliably handling and accurately positioning the constituent core laminations, which number in their thousands, during transformer core construction. Technical evaluation of the proposed pick-and-place core assembly system, incorporating two mobile robots bearing a common gripper, is presented herein to address these requirements. A unique robotic gripper, having the capability to selectively pick a given number of steel laminations (typically two or three) concurrently from a stack, has the potential to significantly increase productivity. The only available avenue for picking multiple laminations was deemed to be a gripper based on magnetism. Closed form analytical and finite element models for an electromagnet-stack system were contrived and their force distributions obtained. The theoretical findings were validated by experiment using a specially constructed prototype. Critical parameters for reliably lifting the required number of laminations were identified and a full scale electromagnet, that overcame inherent suction forces present in the stack during picking, was subsequently developed. A mechanical docking arrangement is envisaged that will ensure precise lamination placement. Owing to the grippers unwieldy length however, conventional robots cannot be used for assembling larger cores. Two wheeled mobile robots (WMRs) compliantly coupled to either end of the gripper could be considered although a review of the current literature revealed the absence of a suitable controller. Dynamic modelling for a single WMR was therefore undertaken and later expanded upon for the dual WMR system conceived. Nonlinear adaptive controllers for both WMR systems were developed and subsequently investigated via simulation. Neglecting the systems dynamics resulted in analogous, simplified kinematic control schemes, that were verified experimentally using prototypes. Additional cooperative control laws ensuring the synchronisation of the two robots were also implemented on the prototype system.

Report (M. Eng.)--Virginia Polytechnic Institute and State University, 1994. / Abstract. Includes bibliographical references (leaf 85). Also available via the Internet.

Thesis (M.Phil.)--Hong Kong University of Science and Technology, 2005. / Includes bibliographical references (leaves 96-99). Also available in electronic version.

Thesis (M.Eng.Sc.) - University of Queensland, 2002. / Includes bibliography.

Thesis (M.S.)--University of Wisconsin--Madison, 1967. / eContent provider-neutral record in process. Description based on print version record. Includes bibliographical references.

Thesis (M.S.) University of Missouri-Columbia, 2006. / The entire dissertation/thesis text is included in the research.pdf file; the official abstract appears in the short.pdf file (which also appears in the research.pdf); a non-technical general description, or public abstract, appears in the public.pdf file. Title from title screen of research.pdf file (viewed on August 23, 2007) Includes bibliographical references.

Manual lifting is dynamic in nature and involves asymmetrical loading of the human body. This study investigated kinematic and kinetic characteristics of asymmetrical lifting in three dimensions, and then constructed a 3-D biomechanical force model of the lower back which is capable of quantifying torsional stress on the human spine. Eleven healthy adult male manual workers were recruited as subjects and lifted a 1 Okg load placed at the sagittal plane (0°) and at 30°, 60° and 90° lateral planes to the right, from 150mm and 500mm initial lift heights, respectively, to an 800mm high bench in the sagittal plane. Subjects' spinal motions and the trajectorial movements of the load in three-dimensional space were monitored simultaneously by a Lumbar Motion Monitor and a V-scope Motion Analyzer. Generally, the spinal motion factors increased as a function of increasing task asymmetry and differed (p < 0.05) between the lower (150mm) and higher (500mm) levels in the sagittal plane. In all asymmetrical conditions the motion factors showed a dramatic increase at the 500mm level compared to the increase at the 150mm level. The rates of increase in the horizontal and frontal planes were greater than those in the sagittal plane. Task asymmetry had a significant effect on the spinal kinematic parameters in the frontal plane at the two lift heights, and only at the high level (500mm) in the horizontal plane, with exception of average acceleration . Initial lift height exerted a significant effect on peak velocity and acceleration in both frontal and horizontal planes and on range of motion in the horizontal plane. Kinetic characteristics of the object being lifted in three-dimensions increased with an increase in task asymmetry. The increase was more dramatic in the lateral direction in the horizontal plane. However, motion factors in the vertical direction dominated the full range of the lift, irrespective of task asymmetry and lift height. The kinetic measures differed (p < 0.05) between the lower ( 1 50mm) and the higher (500mm) levels in the vertical direction except for average force. Task asymmetry had a significant effect on dynamic measures in the anterior-posterior direction. Both task asymmetry and lift height had a significant effect on dynamic motion factors in the lateral direction. From insights gained in the empirical study a three-dimensional biomechanical force model of the lower back was constructed based on a mechanism of muscle force re-orientation in the lumbar region. Acknowledging that the lower back is designed to be able to rotate around its longitudinal axis, the proposed model accounts for compression and shear forces and a torsional moment. The model has similar predictability to Schultz and Andersson's (1981) model when the human trunk exerts only a flexion-extension moment in the sagittal plane, but additionally predicts dramatic increases in shear forces, oblique muscle forces and torsional moment under asymmetrical lifting conditions which the Schultz-Andersson model does not. The increase rates in these forces and moment are not linearly related over task asymmetric angle.

South African SMMEs, just like their counterparts world-wide, play a very crucial role against the world economies. The competiveness of these SMMEs is therefore very important. Lean Manufacturing and its principles have been successfully applied by motor manufacturing industries over the years. Many other organisations has since followed suite and adopted lean manufacturing as an approach to optimise and better manage their resources while providing value to their customers. The objective of this study is to investigate how lean manufacturing techniques can be adopted by a specific SMME in a business of manufacturing security products for the banks to better manage its material flow and improve its competitiveness. The research uses observation method to gather information to develop the current value stream map and identify the wasteful procedures. The also involves the interviewing of staff members that are involved in the material handling within the organisation. The results from the two processes are explained and the future value stream map incorporating the lean techniques is developed and presented to the organisation.