e-design methods and tools to facilitate manufacturing process optimization

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01111100101101010100101010National Science Foundation Industry/University Cooperative Research Center for e-Design: IT-Enabled Design and Realization of Engineered Products and Systems

UMassAmherst

e-Design Methods and Tools to Facilitate Manufacturing

Process OptimizationDouglas Eddy, Dr. Ian Grosse, Dr. Sundar

Krishnamurty, Dr. Jack Wileden

UMass Amherst

National Science Foundation Industry/University Cooperative Research Center for e-Design

NSF I/UCRC Center for e-Design Summer 2010 IAB Meeting 2

Project Status

Project Type: Continuing Research Thrust Area: Design Optimization Percent Complete: 30% Start Date: 2/16/10 Expected Completion Date: 12/31/10 Funding

– NSF Program Funds - 0%– Other Funds - 100%

National Science Foundation Industry/University Cooperative Research Center for e-Design

NSF I/UCRC Center for e-Design Summer 2010 IAB Meeting 3

Problem Statement

Small sized industry partners do not always have internal engineering design capabilities.

A market opportunity exists for a more functional design.

The process could enable the collaborative transfer of e-Design knowledge.

National Science Foundation Industry/University Cooperative Research Center for e-Design

NSF I/UCRC Center for e-Design Summer 2010 IAB Meeting 4

Approach and Methods Three different potential design concepts

identified:

Cable on Pulleys Straps on Pins Roller Chain Option

Use the e-Design Ontology’s framework for:– FEA and ANSYS analysis– Design decision process– Design optimization

National Science Foundation Industry/University Cooperative Research Center for e-Design

NSF I/UCRC Center for e-Design Summer 2010 IAB Meeting 5

Related Works Drawbacks with current design:

– Exhibits sway greater than 20”– Breakage of cables after about 350 cycles– Quick release can cause the mast to come crashing

down

Competitor products: – Costly– Rise to the 30 feet height

can take significantly longer than the desired speed for the payload

National Science Foundation Industry/University Cooperative Research Center for e-Design

NSF I/UCRC Center for e-Design Summer 2010 IAB Meeting 6

How Ours is Different Design process utilizes high end design

methods and tools to verify and validate.

Provides knowledge of the interoperability between two different CAD systems (Pro/E and Solid Works)

Technology Transfer of design knowledge from UMass e-Design team to an industry partner

Captures and maintains semantic information using UMass Amherst’s ontology-based e-Design framework

National Science Foundation Industry/University Cooperative Research Center for e-Design

NSF I/UCRC Center for e-Design Summer 2010 IAB Meeting 7

Deliverables and Benefits

Deliverable:– A completely developed and validated design

specification to enable production.

Benefits:– Ontology knowledge instance information– Sales in an initial estimated quantity of 1000 – 3000 – Creation of 50-60 jobs in the Precision Machining

sector of the Western Massachusetts region

National Science Foundation Industry/University Cooperative Research Center for e-Design

NSF I/UCRC Center for e-Design Summer 2010 IAB Meeting 8

Project Plan 1) Development of several proof of design concept prototypes – 3 months

2) Evaluation of design options using the e-Design framework – 1 month

3) Development and/or modification for optimization – 1 month

4) Identification of Critical Function Features, Quality Control Plan, FEA

analysis, and Design for Manufacturability and Assembly (DFMA) – 1 month

5) Theoretical Design Validation to enable a prototype build – ½ to 1 month

6) Completion of prints/specifications for manufacturing – ½ to 1 month

7) Refinement and improvements based on results – 1 to 2 months

8) Reliability analysis – 1 to 1 ½ months

9) Create an ontology instance – 1 to 1 ½ months