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Measurement Methods for Flux Residue Quantity after Controlled Atmosphere Brazing of Aluminum Coolers

Nadolny Sławomir, Hamrol Adam, Rogalewicz Michał, Piasecki Adam

Management and Production Engineering Review

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2023

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Vol. 14, No. 3

156--163

EN

The Controlled Atmosphere Brazing (CAB) process together with NOCOLOKr flux is associated with the occurrence of potassium fluoroaluminate residue inside the cooler. Excess of this flux residue is known to cause gelation of the coolant, which deteriorates the efficiency of the cooler. The flux residue amount is most often measured via Atomic Absorption Spectroscopy (AAS), in accordance with DIN ISO 9964-3. This is a time-consuming measurement that requires the use of specialized equipment and costly solvents. The following article presents two innovative methods for flux residue measurement after CAB process. They include Scanning Electron Microscopy (SEM) with Energy-Dispersive X-ray Spectroscopy (EDS) and Reflected Light Microscopy (RLM) with Differential Interference Contrast (DIC) module. The accuracy of these methods has been compared to the reference AAS method to evaluate their potential as alternative, less expensive, and quicker measurement methods for determining the quantity of flux residue.

2

Ensuring the reliability and reduction of quality control costs by minimizing process variability

Rogalewicz Michał, Kujawińska Agnieszka, Feledziak Adrianna

Eksploatacja i Niezawodność

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2023

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Vol. 25, no. 2

art. no. 162626

EN

This paper presents a method for planning the range of quality control while ensuring its reliability and minimizing costs. The method is dedicated to destructive inspection, in which the cost of performing the measurement is significant in relation to the cost of manufacturing a part or product. The methodology was divided into four main stages: (1) selection of the measurement system and definition of the inspection scope and sample size, (2) process control, (3) redefining the scope of control and (4) verification of control cost and reliability after sample size change. The article presents the results of applying the author's procedure to the process of evaluating seat belts in automotive industry. Belts are used in the process of controlling the final product, which is a seat belt anchor plate. This approach allowed to reduce the number of destroyed parts during control while maintaining the credibility of the decision based on the assessment. As a result of double-decreasing the sample size, the costs of seat belt quality control were reduced. Assuming an average of 40 seat belt deliveries per year, the material cost was reduced by 50%. Limiting the sample size to 15 pieces per delivery would reduce the cost of testing from by 45%. It was achieved maintaining the appropriate level of credibility of decisions made greater than 0.8.

3

Optimization of the Conveyor Line System Using Computer Simulation on the Example of a Modern Warehouse

Gawron Eryk, Sika Robert, Rogalewicz Michał

Advances in Science and Technology. Research Journal

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2023

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Vol. 17, no 1

304--314

EN

The paper presents a outline of a modern large-area warehouse of an enterprise engaged in the sale of, among others, food products, software, books, automotive components, and many others. The techniques, methods, research and design tools used were described. A control system was designed, its plan and network connections of control devices based on the characteristics of technological documentation. The design of logical structures controlling the conveyor line, network topology configuration and also the safety system was proposed. The performance and errors of the line were checked in the simulation process. The paper also includes the process of commissioning and testing an industrial PLC (Programmable Logic Controller) on a real object, which is a modern warehouse.

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Mechanical properties and geometric accuracy of angle-shaped parts manufactured using the FFF method

Kuczko Wiesław, Hamrol Adam, Wichniarek Radosław, Górski Filip, Rogalewicz Michał

Bulletin of the Polish Academy of Sciences. Technical Sciences

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2021

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Vol. 69, nr 3

art. no. e137387

EN

The paper presents the results of research on the influence of the parameters of Fused Deposition Modelling (FDM) on the mechanical properties and geometric accuracy of angle-shaped parts. The samples were manufactured from acrylonitrile butadiene styrene (ABS) on a universal machine. A complete factorial experiment was conducted. The results indicated that the critical technological parameter was the angular orientation of the sample in the working chamber of the machine. The results were compared with the results of research performed on simple rectangular samples. A significant similarity was found in the relationships between the FDM parameters and properties for both sample types.

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Selection of an industrial robot for assembly jobs using multi-criteria decision making methods

Suszyński Marcin, Rogalewicz Michał

Management and Production Engineering Review

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2020

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Vol. 11, No. 1

62--72

EN

The paper proposes three multi-criteria decision-making (MCDM) methods for the selection of an industrial robot for a universal, flexible assembly station, taking into consideration the technical and performance parameters of the robot. Fuzzy versions of AHP and TOPSIS methods as well as SMART were chosen from the variety of MCDM methods as they represent different attitudes to analysis. In order to minimise the impact of the method applied on the final decision, a list of results of the analyses has been developed and a final classification has been made based on decision makers’ preferences concerning selected parameters of the robot

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The methodology of acquisition and statistical analysis of data from the process of drying thin wooden elements

Kujawińska Agnieszka, Rogalewicz Michał, Diering Magdalena, Żywicki Krzysztof, Hoffmann Piotr

Drewno : prace naukowe, doniesienia, komunikaty

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2020

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vol. 63, nr 205

43--58

EN

This paper presents an original methodology of acquisition and statistical analysis of data from the process of drying thin wooden items, without interference in the manufacturing schedule or process. The research was aimed at reducing the duration of the lamella drying process in a convectional drying chamber, and minimising non-conformities of dry lamellas. The authors discuss the effective application of convectional drying methods, taking into consideration non-homogeneous wood quality resulting from over- or under-drying caused by uneven or insufficient exposure to the drying agent, long duration of the drying process serving to minimise the internal stress of the material, poor efficiency of the drying process, and relatively high operational costs. Based on the tests performed, a quick drying programme is recommended. To reduce the fraction of non-conforming lamellas, the authors suggest that the arrangement of lamellas in the cage be changed so that all lamellas are protected against unconstrained deformation.