Purpose: The thesis investigates the automation of screwing operation on moving assembly line, that can be integrated with the current workflow using automation technology and collaborative robots. The study focuses on reducing the number of manual tasks in screwing operation while considering the ergonomics and safety factor of the operator.    Method: The study uses mixed methods research approach, such as interviews and observation, along with literature review on the desired topics. The study focus on details of the company and their production layout. Practical challenges are derived from the combination of data, providing a guidance on developing an automated solution.    Findings: The research questions were answered, using the data derived from the interviews. The empirical data was compared with the theoretical data to enhance the validity. The resulted data identified to develop a new concept to satisfy all the technical functions.    Implications: The research finds out that a collaboration with an industrial robot, can help the operators to perform desired task. The robot needs to be supported with other aspects such as motion of robot, monitor system and safety. The research identified a conceptual design to overcome these challenges, and to change the production layout to accommodate them is recommended.    Delimitations: The study is focused on the screwing technology on a moving assembly line, and a concept is developed to overcome the challenges. There is no prototype constructed, the proposed idea is designed in robot studio to showcase the idea.    Keyword: Moving assembly line, Human-robot collaboration, Screwing technology, Automated screwing technology, industrial robots, Automobile manufacturing

L'utilisation croissante des polymères dans les structures industrielles est impulsée par le besoin de réduction du cycle/coût de production ainsi que de l'allègement des structures. Dans l'industrie automobile, PSA Peugeot Citroën s'est lancé sur une problématique liée au dimensionnement d'un procédé d'assemblage de pièces plastiques par vissage-taraudage. Le principe du procédé consiste à réaliser le taraudage directement lors du montage de la pièce <<portée>> en polymère en utilisant une vis métallique auto-taraudeuse. Il s'agissait alors d'être capable de modéliser numériquement par éléments finis l'opération de vissage-taraudage. Cet outil numérique offre ensuite la possibilité de mener des plans d'expériences plus larges en étudiant l'influence d'un plus grand nombre de paramètres à des fins d'optimisation de procédé d'assemblage impliquant les polymères. Les premières investigations ont montré qu'il s'agissait d'un problème thermo-mécanique complexe où toutes les composantes de déformation des matériaux polymères sont sollicitées : élastique, visqueuse, plastique et volumique. La démarche suivie est donc celle de l'approche locale de la rupture qui nécessite des observations fines des micro-mécanismes de déformation et d'endommagement suivies d'une modélisation par éléments finis s'inspirant de ces micro-mécanismes. Les données expérimentales se basent sur les variables mesurables à partir des essais mécaniques, enrichies par des observations en tomographie X. Cette technique non destructive révélant des images en 3D a permis de caractériser la morphologie et la distribution de la porosité en fond de filet. La prise en compte de cette porosité a été réalisée à l'aide d'un modèle issu de la mécanique des milieux poreux : le modèle de Gurson-Tvergaard-Needleman adapté aux matériaux polymères. Le modèle identifié a permis de construire un diagramme sur lequel peut s'appuyer le choix de la vitesse de rotation optimale du procédé de vissage-taraudage. Une alternative consistant en un assemblage de type vis polymère/écrou polymère a été également étudiée. Grâce à l'approche locale dont le critère de rupture est basé sur la porosité critique, le point faible de l'assemblage ainsi que sa tenue mécanique présumée à partir du niveau d'endommagement atteint en ce point ont pu être estimés. / The increasing use of polymers in engineering structures is promoted by the need to reduce both cycle/cost production and the weight of these structures. PSA Peugeot Citroën initiated research works to design the assembling process using metallic screwing/threading on polymers. It consists in directly taping the polymeric piece during the mounting operation by using self-threading metallic screw. The final objective of the work deals with the ability to numerically (finite element) model the screwing/threading operation. This numerical tool offers the possibility to perform a large campaign of study highlighting the sensitivity of the assembly procedure to a significant range of parameters. The first investigations showed that this problem consisted of complex thermo-mechanical loading for which all the deformation components of the polymeric material were involved: elastic, viscous, plastic and volumetric. The study was performed within the framework of the local approach to fracture, that required fine examinations of the micro-mechanisms of deformation and damage within the polymer. The experimental database were composed of measurable variables obtained from mechanical tests together with a comprehensive X-ray tomographic inspections. This latter non destructive technique revealing 3D images of the deformed microstructure allowed for characterization of the morphology and the distribution of voids within the polymer in the vicinity of the crest. To account for void volume fraction, a model from the mechanics of porous media was utilized: the Gurson-Tvergaard-Needleman model, modified for polymeric materials studies. The present model allowed for a construction of a failure assessment diagram that would permit to optimize the screwing rotation speed of the screwing-tapping process. An alternative solution consisting of an assembly composed of polymeric screw and polymeric nut was additionally investigated. Thanks to the local approach of fracture criterion based on the critical porosity, the weakest point of the assembly as well as its mechanical residual strength were estimated.

The main objective of the master’s thesis is to study the influence of phosphate coating structure on the mechanical properties of screw connection. The theoretical part describes the conventional phosphating process and it is followed by an analysis of current knowledge of phosphating technology. Experiments are carried out on screw valves mounted to a high pressure diesel pump by Bosch Diesel s.r.o., made of unalloyed carbon steel. To investigate the effect of the structure on the connection sealing, twelve kinds of phosphate coatings varying in one process parameter were prepared. The monitored parameters determining the phosphate structure are – type of phosphate and activation bath, its temperature and concentration and time of immersion. The sealing connection is examined during simulated assembly process by angle controlled tightening while measuring torque and permanent material deformation. Prepared layers are characterized by determination of weight per unit area and their structure observed by electron microscope.