Motion and timing analysis of the handling process
for unloading a fast injection mold machine helped to
redesign part handling and optimize the control system
timing. Cycle time improvements of more than 5% were
Pickup of chips from a supply tape yielded random loss
of components. Lost components caused further damage
and maintenance was increased. A high speed video showed
the systematic of the pickup errors. Vacuum supply and
pickup tools were adjusted. Machine uptime and placement
quality was significantly increased, line throughput
was back on target.
Motion analysis of fast moving pick and place devices
was carried out to optimize machine and process performance.
Slow motion process studies revealed multiple options
for better dynamic drive tuning and control timing.
Accelerations and inertia reactions were minimized.
Mechanical wear and machine vibration was significantly
reduced. Overall performance in high speed applications
was increased over 8%.
Cardboard box handling had random failures which caused
lost, partly unfolded boxes to block the machine and
stop the packaging line. A slow motion analysis revealed
the reasons for the random failure -- a slight misadjustment
of the handling device and wear of the vacuum pickup.
Timing analysis with PLC signals shown in the slow motion
sequence showed poor timing of the process. Together
all problems had brought the system to the edge of a
safe process window. All causes could be fixed within
the same day. The line now worked better than specified.
Crimp tools of manual feed machines showed an increasing
amount of malfunctions at a customer's site. The machine
and tool manufacturer had replaced experienced tool
design staff with young, inexperienced engineers. They
did not know about the many little details that made
a well designed tool work properly, as their predecessors
had. Systematic high speed analysis at the customer's
production site clearly showed the nature of malfunctions.
The young engineers learned a lot within a short period
of time. Tool quality is now almost back to normal and
the problems were solved by using high speed video.
For better understanding of failure mechanisms in automotive
headlights, high speed video was used. A new design
had to be found to achieve the specified product lifetime.
Slow motion studies contributed significantly to better
design details of the spiral-wound filament suspension.
All airbag manufacturers are legally obliged to do
statistical quality control using high speed video to
document the proper functioning of airbags. Parachutes
are tested as to their unfolding; multiple protective
devices in street traffic are optimized after slow motion
Drop tests, longitudinal and lateral break load test,
flexion and elasticity tests, dynamic deformation of