A new torque transfer standard using metallic TBTF resonant sensor was developed to overcome the overload capability problem which occurs with conventional metallic resistance strain gauges. Previous research work, however, has shown that the first prototype of the metallic TBTF resonant sensor was not suitable for use in a torque transfer standard due to its size and subsequent sensitivity to parasitic lateral forces. To maximize the benefits from this sensor, particularly overload capability and long-term stability, in the high accuracy torque measurement application area, there is a need to develop significantly smaller devices. The aim of this thesis is to research through FEA modelling and experimental characterisation the key performance parameters required to produce a miniaturised metallic TBTF resonant sensor that provides better performance when applied in a torque measurement system. For high accuracy any torque transducer using these sensors ought to have low sensitivity to parasitic influences such as bending moments and lateral forces, which can only be achieved with reduced size. The problems with the existing design, key design issues, possible configuration and packaging solutions of the metallic TBTF resonant sensor that could be used for achieving a higher accuracy torque transfer standard are considered. Two designs of miniaturised metallic TBTF resonant sensors, SL20 and SL12, are considered and experimentally investigated. The lateral forces are reduced by 52% for SL20 design and by 80% for SL12 design when compared to the original SL40 design. A torque transducer using the SL20 design was calibrated falling into the Torque Transfer Standard class of accuracy 1 category, uncertainty 0.8%. A torque transducer using the SL12 design was made and calibration showed a class of accuracy 0.5 category, uncertainty 0.2%. The results from this research indicate that the SL12 design is suitable for use in a torque transfer standard. The SL12 design is optimal and the smallest size possible based on the overload capability design criteria requiring the tine cross sectional area to remain constant.

The thesis is concerning rotator assembly at Indexator. A need to increase production has been seen and it can be done by implementing an optimized assembly process. In addition to the assembly process a new design on workstations and new test equipment is needed.The study resulted into three assembly process proposals. The processes were balanced, layouts were produced and Plant simulation was utilized to produce simulation models. Each proposal were analyzed based on cost, performance, ease of implementation, flexibility and worker condition. This resulted in a stationary assembly process being most promising and a 3D simulation model was produced for visualization and better understanding. The stationary assembly process has a capacity for 90 rotators per day, while reducing the amount of workers by one.The layout of the workstations was done based on the assembly process layout and further developed to make the work cell lean and ergonomic. It resulted in three workstations to perform the assembly. The test bench was developed by creating target specifications, establish a test procedure and decide components for the test bench layout. The finished test bench can measure dynamic torque, count particles to ensure cleanliness and is able to run the test unattended. / Examensarbetet handlar om montering av rotatorer på Indexator. Målet är att ta fram en optimerad monteringsprocess som kan implementeras i Indexators fabrik utan svårigheter. Den nya monteringsprocessen kommer kräva en ny design på arbetsstationerna och nya testbänkar.Fyra koncept på monteringsprocessen togs fram, baserat på monteringens behov och målsättning. Efter utvärdering så modifierades de fyra koncepten till tre förslag på monteringsprocesser. Processerna balancerades, layouter utvecklades och simuleringsmodeller producerades för varje process. Varje förslag analyserades baserat på kostnad, prestanda, implementation,flexibilitet och arbetar-förhållande. Resultatet blev en stationär monteringsprocess och en 3Dsimulering gjordes för visualisering och förståelse. Den stationära monteringsprocessen har en kapacitet på 90 rotatorer per dag och reducerar behovet av montörer.Layouten för monteringsstationerna baseras på processens layout och har modifierats för ergonomiska aspekter. Inom monteringsstationerna så utvecklades layouten för att minimera antalet onödiga rörelser för montören. Testriggens design utvecklades genom att analysera de behov som fanns, skapa en kravspecifikation samt utvärdera och besluta om testprocedur, upplägg för testrigg och dess ingående komponenter. Testriggen uppfyller målsättningen som är att kunna mäta dynamiskt vridmoment, räkna partiklar för att säkerställa renhet i rotatorn och kunna utföra testningen självgående för att frigöra montören under testprogrammet.