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ModularDesignandDocumentationof
ConstructionEquipmentHoodsusingDassaultSystemes3DExperiencePlatform
MURALI KRISHNA SATHYA NARAYANAN
Department of Product and Production Development
CHALMERS UNIVERSITY OF TECHNOLOGY Gothenburg, Sweden 2015
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Modular Design and Documentation of Construction Equipment Hoods using Dassault Systemes 3DExperience Platform MURALI KRISHNA SATHYA NARAYANAN © MURALI KRISHNA SATHYA NARAYANAN Department of Product and Production Development CHALMERS UNIVERSITY OF TECHNOLOGY Gothenburg, Sweden 2015 SE – 412 96 GOTHENBURG Sweden Telephone +46 (0)31-772 1000 Cover: Modular Design and Documentation of Construction Equipment Hoods using Dassault Systemes 3DExperience Platform © Murali Krishna Sathya Narayanan, 2015
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ABSTRACT Modular Design and Documentation of Construction Equipment Hoods using Dassault Systemes 3DExperience Platform ByMuraliKrishnaSathyaNarayanan,
DepartmentofProductandProductionDevelopment,
ChalmersUniversityofTechnology,
Inordertoreducetheproductcomplexityandfindsynergiesbetweendifferentproduct
categories, Volvo Construction Equipment has started an initiative called Common
Architecture Shared Technology (CAST), which concentrates on establishing the
modular product architecture for different components in a vehicle. CAST helps in
reducingthecomplexityoftheproductsbyunderstandingthefunctionalrelationshipto
thedesignandtherebyidentifyingsynergieswhichwillhelpincommonizingparts,thus
reducingthepartnumbers.TheMasterthesismainlyconcentratesonthehoodsoffive
productcategories.Thegenericproductdevelopmentmethodologydefinedinthebook
“ProductDesignandDevelopment(UlrichandEppinger,2012)andVCE’sinternalCAST
methodologyareusedasguidancethroughouttheproject.
The3DXplatformfromDassaultSystemesisusedtodocumentthemodularsolutions.
The3DXplatformhelpsincapturingrequirements,allocatingthemtodifferententities,
defining different configuration features and options based on technical rules and
creatingdifferentproductconfigurations.
The study helped in identifying the synergies in design between the five product
categoriesbyfunctionallydecomposingthedifferenthoodsandfindingtherelationship
both within and between product categories. This resulted in a modular product
architecturewhich helped to reduce the number of parts from 32 to 26 and further
down to20by theproposed changes.Thedifferentmodulesweredefinedusing3DX
platform and various technical rules were established to show different possible
configurationsofhoods.
Keywords: Synergy, functional breakdown, CAST, technical rules, capturing
requirementsconfigurations
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ACKNOWLEDGEMENTS This report, “Modular Design and Documentation of Construction Equipment Hoods using
Dassault Systemes 3DExperience Platform” is written as a Master’s thesis during the fall of
2014. It is the final project for the MSc. Program of Product Development. This thesis is a
collaboration between Volvo Construction Equipment and Dassault Systemes.
Firstly, I would like to thank my supervisor and mentor at Dassault Systemes, Lars Tengelin
for all the support and encouragement provided at each and every stage of the project work
and the guidance provided during the reviews.
With profound respect, I express my deep sense of gratitude and sincere thanks to the team
at Volvo Construction Equipment. Especially Lars Jung, Sofia Hällgren, David Carlson and all
the people who have contributed to the project.
I would also like to express my sincere thanks to my Supervisor and examiner, Lars Lindkvist
(Docent) at Chalmers University for providing all the guidance and reviews in order to make
the project more successful.
I would like to add a special thanks to Frederic Penso and Francois Sychowicz for all the
extended support provided throughout the project.
Lastly I would like to offer my best regards to all those who supported me in any respect
during the course of the project.
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NOMENCLATURE
DS ‐ Dassault Systemes
VCE ‐ Volvo Construction Equipment
3DX ‐ 3DExperience Platform
CATIA ‐ Computer aided three dimensional interactive application
ENOVIA ‐ Enterprise innovation interactive application
CAD ‐ Computer Aided Design
PLM ‐ Product Life Cycle Management
USP ‐ Unique Selling Point
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TABLE OF CONTENTS
ABSTRACT ............................................................................................................................ I
ACKNOWLEDGEMENTS ...................................................................................................... III
NOMENCLATURE ................................................................................................................ V
TABLE OF CONTENTS ........................................................................................................ VII
1. INTRODUCTION ........................................................................................................... 1
1.1 BACKGROUND.........................................................................................................................................................1
1.2 AIM & PURPOSE.....................................................................................................................................................2
1.3 SCOPE.......................................................................................................................................................................2
1.4 LIMITATION.............................................................................................................................................................3
1.5 DELIVERABLES.........................................................................................................................................................4
2. NEEDS MAPPING ......................................................................................................... 5
2.1 DATACOLLECTIONMETHODS........................................................................................................................5
2.1.1 LITERATURESTUDY......................................................................................................................................................5
2.1.2 INTERVIEWS......................................................................................................................................................................5
2.2 ESTABLISHINGREQUIREMENTSSTRUCTURE...........................................................................................5
2.2.1 GENERICREQUIREMENTSTRUCTURE.................................................................................................................6
2.2.2 FEATUREBASEDREQUIREMENTSTRUCTURE................................................................................................8
2.3 MAPPINGREQUIREMENTS...............................................................................................................................9
2.4 FUNCTIONALBREAKDOWN.............................................................................................................................9
2.5 INTERFACEANALYSIS......................................................................................................................................11
3. CONCEPT DEVELOPMENT .......................................................................................... 12
3.1 CONCEPTDEVELOPMENTMETHODOLOGY..............................................................................................12
3.1.1 GENERALMETHODOLOGY.......................................................................................................................................12
3.1.2 MODULARARCHITECTUREDEFINITIONPROCESS.....................................................................................12
3.2 CONCEPTGENERATION...................................................................................................................................14
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3.2.1 SHAPEDRIVERS............................................................................................................................................................14
3.2.2 DIMENSIONANALYSIS...............................................................................................................................................20
3.2.3 BENCHMARKING..........................................................................................................................................................33
3.2.4 CONCEPTGENERATION............................................................................................................................................37
3.3 ARCHITECTUREDEFINITION.........................................................................................................................38
3.3.1 SIDEPANELARCHITECTURE..................................................................................................................................38
3.3.2 TOPPANELARCHITECTURE...................................................................................................................................40
3.3.3 GRILLEARCHITECTURE............................................................................................................................................41
3.3.4 MODULARHOODARCHITECTURE.......................................................................................................................44
4. TECHNICAL DOCUMENTATION .................................................................................. 46
4.1 REQUIREMENTMANAGEMENTMODULE...................................................................................................46
4.1.1 FEATURESOFTHEREQUIREMENTMANAGEMENTMODULE...............................................................47
4.1.2 EXAMPLEOFREQUIREMENTMANAGEMENT‐MODULARHOODDESIGN......................................47
4.2 VARIANTMANAGEMENTMODULE..............................................................................................................48
4.2.1 DEFINITIONOFCONFIGURATIONFEATURESANDCONFIGURATIONOPTIONS...........................49
4.2.2 CONFIGURATIONFEATURESANDOPTIONS...................................................................................................49
4.2.3 FEATURESOFTHEVARIANTMANAGEMENTMODULE............................................................................50
4.2.4 EXAMPLEOFCONFIGURATIONFEATURESANDOPTIONS‐MODULARHOODDESIGN............50
4.2.5 DEFINITIONOFCONFIGURATIONRULES........................................................................................................51
4.2.6 EXAMPLEOFCONFIGURATIONRULESANDMARKETINGPREFERENCES.......................................52
4.3 CADINTERFACE.................................................................................................................................................54
4.3.1 DEFINTIONOFEFFECTIVITIES..............................................................................................................................54
4.3.2 PRODUCTCONFIGURATION....................................................................................................................................55
5. MANUFACTURING METHODS ................................................................................... 57
5.1 MODULARDESIGN‐CHALLENGESINMANUFACTURING.....................................................................57
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5.2 DESIGNFORASSEMBLY...................................................................................................................................57
5.2.1 DESIGNOFINTERFACES...........................................................................................................................................58
5.2.2 DESIGNOFGRILLE.......................................................................................................................................................60
5.3 COSTANALYSIS..................................................................................................................................................61
6. DISCUSSION .............................................................................................................. 62
6.1 DISCUSSIONONNEEDSMAPPING................................................................................................................62
6.2 DISCUSSIONONTHECONCEPTDEVELOPMENT......................................................................................62
6.3 DISCUSSIONONTHETECHNICALDOCUMENTATION............................................................................63
6.4 DISCUSSIONONTHEMANUFACTURINGMETHODS...............................................................................64
7. CONCLUSIONS AND RECOMMENDATIONS ................................................................ 65
7.1 IMPORTANTFINDINGS....................................................................................................................................65
7.2 RECOMMENDATIONS.......................................................................................................................................65
REFERENCES ..................................................................................................................... 67
APPENDIX I ....................................................................................................................... 68
APPENDIX II ...................................................................................................................... 71
APPENDIX III ..................................................................................................................... 75
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1. The
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existing problem diminishing design quality and increasing time to market
(Gokpinaretal.2013).
One of the preferred solutions to the above challenge is to develop a modular
architecture fordifferent componentswhichwillhelp in increasing thenumberof
commonpartsandatthesametimeofferawiderproductrange.
The 3DX platform from Dassault Systemes is used to document the modular
solutions, Dassault Systemes is a world leader in 3D and Product Lifecycle
Management (PLM) solutions. The 3DX platform offers a unique digital product
experience that brings 3D product design to life with unmatched realism and
deliveringcollaborativePLMsolutions.
1.2 AIM & PURPOSE Inordertoreducetheamountofpartnumbersandtoofferawiderproductrange,a
CommonArchitectureandsharedtechnology(CAST)strategyhasbeenadoptedby
VCE. The main purpose of the study is to define a Modular architecture, as a
technicalsolution,forhoods.Theproductcategoriesthatareincludedinthestudy
are Articulated Haulers, Wheel Loaders, Soil Compactors, Backhoe Loaders and
MotorGraders.
Thestudyincludesthefollowingtasks
Functionaldecompositionofthehoodsanditsassociatedcomponents
Benchmarkingvariousmodulardesigns
Designinganddocumentingamodulararchitecture
Identifying allowed/rejected combination of parts based on design criteria
and technical feasibility which enables the creation of better product
architecture
Thesecondaryobjectiveoftheprojectwouldbetotestrunthemodulararchitecture
of the hood on Dassault System’s 3DX platform. This requires understanding of
CATIAandENOVIAenvironmentandalso theconfigurationenginewhichcontrols
thevariantmanagement(Baldwin&Clark1997).
1.3 SCOPE The Scope of the project has two dimensions. Onewould be the definition of the
modules, the design rules, performance steps and technical feasibility of different
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components.Theseconddimensionoftheprojectwouldbetotestrunthemodular
architectureonthe3Dexperienceplatformwhichinvolvesthefollowingactivities
CreationofmodulesinCADandsynchronizingwith3DExperienceplatform
Capturing the customer requirements, design criteria and the technical
feasibilityin3DExperienceplatform
Definingthevariantrulesandconfigurationin3DExperienceplatform
Demonstrationofthesoftware’scapabilities
Theproductcategoriesandtheirrespectivemodelswhichwillbecoveredunderthe
studyareshowninTable1.Modelsaregroupedbasedoncommonalityofhoods.
Table1:ProductCategoriesandModels
Product Categories Models
Articulated Haulers A25G/A30G
A35G/A40G
Compact Wheel Loaders
L20F
L30G
L45G/L50G
General Purpose Wheel Loaders
L60H/L70H/L90H
L110H/L120H
L150H/L180H
L220H/L250H
Motor Graders G930C
G940C/G946C/G960C
Backhoe Loaders BL60B‐BL70B
Soil Compactors
SD25
SD45
SD70
SD75
SD115‐SD135
SD105‐SD130‐SD160‐SD190‐SD200
1.4 LIMITATION TheScopeof theprojectwillbe limited toonly theabovementioned fiveproduct
categoriesduetothepossiblesynergiesthatwereidentifiedbeforethestartofthe
project.Thenumberofproductcategoriesmightgodownifthestudyrevealsthere
islesssynergybetweenthem.ThebusinesscaseintheCASTmethodologyislimited
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tothehighlevelduetothetimeconstraints.Thedesignphasewouldbelimitedto
modelingtheparentlevelpartsonly(panels)andwouldnotbeconcentratingonthe
finerdetails.
1.5 DELIVERABLES TheDeliverablesoutofthestudyismentionedbelow
Amodular architecture design for the hood and its interfaces (Module and
Interfacedefinition)
Requirementsandtechnicalfeasibilitydefinitions
CADmodelsofmodulesandinterfacesinCATIAV5andCATIAV6
Performancestepdefinition
Avideoof thevariantmanagementandmodulardefinition for themodular
hoodin3DExperiencePlatform
AmaskedreportagreeduponbyVCEandDSforpublicuse
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2. NEEDS MAPPING Thischapterdescribesthevariousphasesinvolvedinthemappingofneedsinorderto
defineanefficientproductarchitecture.Thedifferentphasesaredescribedbelow
2.1 DATA COLLECTION METHODS Datacollectionfortheprojectwasdoneusingthefollowingmethods
2.1.1 LITERATURE STUDY In order to establish a modular product architecture, it is necessary to identify the
relationshipbetweenfunctionanddesign.Various internaldocumentsfromVCEwere
studied in order to understand the different product categories and their product
structure.
VCE’sproductcatalogueswerestudiedinordertounderstandthespecificationsandthe
featuresofthedifferentproducts.
The modular architecture defined for the cab was used as an example. The
relationships between the requirements and design were clearly mapped for the
modularcabandwereavailablefromthebeginningoftheprojectforreference.
2.1.2 INTERVIEWS Interviewswereconductedwithdifferentstakeholdersinordertoidentifythevarious
requirements.Interviewswereintheformof
‐ Onlinemeetings
‐ Personalinterviews
Onlinemeetingsweremainlydone tocollaboratewithspecialists inhooddesignwho
are outside Sweden. Personal meetings were one‐on‐one face to face interviews
conducted in both Eskilstuna and Braås (Wheel Loaders and Articulated Haulers) in
Sweden. The questionnaires used for the interview and the list of interviewees are
attachedintheAppendixI.
Sincetheprojectcapturestherequirementsdirectlyfromtheengineers,forthisstudy
theneedtoexploreonthemarketingrequirementsissubsided.
2.2 ESTABLISHING REQUIREMENTS STRUCTURE Theoutputoftheliteraturestudyandtheinterviewswereunstructuredanditneeded
tobestructuredinordertoidentifythesynergiesbetweendifferentrequirementsand
its impactondesign.Therequirementscaptured foreachandeverymodel forall the
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plesofspec
mentsetc.
ts hoodiscon
ents truction eq
e driver a
to constr
mentforth
ategoriesun
adistance
isibilityReq
rement uirements
iclesneeds
summariz
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toberaised
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tothosere
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nstrainedo
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uction equ
eentireve
nderstudy
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quirementf
states the
stobeope
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7
manualeffo
dmanually
ncondition
equirement
ementsma
onlybytwo
is of topm
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uipment ac
ehicleisgov
y.Thestand
mtheextrem
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e condition
enwithout
endixII.
ortsrequire
y.Italsode
n.
tswhichar
aybesealin
oregulation
most import
Blind spot
ccidents (H
vernedbyI
dardrequir
mityofthe
uctionvehic
n (wind sp
closingau
edtoopera
scribesthe
reuniquet
ngrequirem
ns.
tance when
accounts
Hinze & T
ISO5006:2
resavisibi
vehicle.
cles(Source
eed) in wh
tomatically
atethehoo
emaximum
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n it comes
to nearly
Teizer 201
2006(Figur
ilityofobje
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hich the h
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ibration
s to the
50% of
1). The
re3)for
ectsata
6)
oods of
dspeed
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2.2.2 This st
functio
configu
Classifi
Openin
Engine
Cooling
Thesel
physica
OpeninOpenin
ofhing
hasadv
asitwi
cab is
imposs
Onthe
hoods
waytha
Engine Theho
Theen
top for
vehicle
FEATURE Btructurede
ning of th
urationfeat
icationofth
ngofHoodw
Inlet/Exha
gInlet/Exh
lectionoffe
alfeatures
g of Hood wngofhoodw
ges,latches
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illinterfere
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otherhand
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atitopens
Inlet/Exhauodprovide
ngine inlet i
r a few. Th
esdonotha
BASED REQUescribes the
he vehicle.
turesandth
hefeatures
withrespe
aust
haust
eaturesisl
aredepend
with respecwithrespec
andthede
feasyacce
ewiththec
overall he
vicecabsin
dopeningo
rkshops.A
awayfrom
ust estheneces
isusuallyp
he engine e
avetheexh
UIREMENT ephysical
This stru
hetechnica
sisdonewi
cttocab
imitedtoth
dentonthe
ct to the cabcttotheca
esignofthe
ssibilityto
cab.Onemo
ight of the
nsidework
ofthehood
proposal i
mthecab.
ssaryprovi
placedont
exhaust for
hauststack
Figure4:
8
STRUCTURfeatures in
ucture play
alrulesint
ithrespect
hemacrol
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b abisveryc
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otheradiat
oreproblem
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riticalwhe
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increases f
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holdingeng
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othereason
nitcomes
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pports the
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an100°
ardsthe
aking it
goflong
n such a
tstacks.
oonthe
el. Some
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CoolingThe ho
system
system
2.3 Based
structu
feature
rulesca
of the
basedr
2.4 Inorde
isnece
breakd
clearly
g Inlet/Exhaood plays
m.Thegrille
mandhasa
MAPPINGon the va
ure,thecap
esandpart
andriveth
mapped re
requiremen
FUNCTIONertoallocat
ssarytofu
down which
brokendo
FrontPane
LeftHand
RightHand
TopPanel
Hoodsupe
aust an import
ehelpsinc
directimpa
REQUIREMarious inte
pturedrequ
ts. After id
heselection
equiremen
ntsissumm
Figure
NAL BREAKtetherequ
nctionally
h is comm
wnintofiv
el(Grille)
panel
dPanel
erstructure
ant role in
channeling
actonthep
MENTS erviews fro
uirementsc
dentifying t
nofthefea
ts is attach
marizedinF
5:Feature
KDOWN irementsto
breakdown
mon for bo
vemainseg
andassoci
9
n providin
gtheaireit
performan
om the de
canbebrok
thecommo
atures(Dah
hed in App
Figure5.
basedrequ
odifferent
nthehood
th design
gments(See
iatedmech
g inlets an
thertowar
ceoftheve
esign speci
kendowna
onanduni
hmusetal.
pendix II. T
uirementm
partsand
.Thehood
and manu
eFigure6)
hanisms(Hi
nd exhaust
dsoraway
ehicle.
alists and
andallocat
que functio
2001).Aco
The mappi
mapping
quantifyth
initselfha
ufacturing.
inges,Latch
ts for the
yfromthe
the requi
tedtothed
ons, config
ompletesu
ing of the
herequirem
asaclearto
The hood
hes,etc.)
cooling
cooling
irement
different
guration
ummary
feature
ments,it
oplevel
can be
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Allthe
allocate
Inorde
the dif
descrip
positio
hood. A
descrip
E
featuresan
edtotheab
ertoavoid
fference in
ption of th
noftheho
A generic
ptionsforth
ENGINEINTHE
ndrequirem
bovementi
Figu
theconfus
n orientat
he hood is
oodinthev
nomenclat
hesamepa
F
EFRONTOFV
mentscapt
ionedpane
ure6:Funct
sioninthe
ion betwe
described
vehicle,the
ture is use
anel.
igure7:En
EHICLE
10
turedfrom
els.
tionalBrea
nomenclat
een differe
d as menti
egrillemes
ed in order
nginePositi
EN
thediffere
akdownofh
tureofthe
ent vehicle
ioned in T
shisalway
r to avoid
oninvehic
NGINEINTHE
ntinterview
hood
moduleso
es (Figure
Table 2. Ir
sreferred
confusions
le
REAROFVEH
wscanbe
ofthegrille
e 7), the
rrespective
asthefron
s due to m
HICLE
edueto
general
e of the
ntofthe
multiple
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11
Table2:HoodNomenclature
GeneralDescription
Positionofhood
Frontofthehoodrefersto
Lefthandsideofthehoodrefersto
Righthandsideofthehood
ArticulatedHauler
Frontofthevehicle
Frontofthevehicle
Lefthandsideofthevehicle
Righthandsideofthevehicle
WheelLoaders
Rearofthevehicle
Rearofthevehicle
Righthandsideofthevehicle
Lefthandsideofthevehicle
BackhoeLoader
Frontofthevehicle
Frontofthevehicle
Lefthandsideofthevehicle
Righthandsideofthevehicle
MotorGraders
Rearofthevehicle
Rearofthevehicle
Righthandsideofthevehicle
Lefthandsideofthevehicle
SoilCompactors
Rearofthevehicle
Rearofthevehicle
Righthandsideofthevehicle
Lefthandsideofthevehicle
2.5 INTERFACE ANALYSIS In order to understand the relationship between the design of the hood and the
surroundingcomponents,atableismappedtoshowtherelationship.Thelevelofdetail
iskepttoaminimumwithrespecttotherelationshipbetweenthedesignofthehood
andtheinterfaceindicatingonlywhetherthereisanimpactonthehoodifthedesignof
theinterfacesischanged.TherelationshipissummarizedinAppendixII.
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3. COThisch
flow of
first fo
archite
3.1 There a
followe
3.1.1 Thege
strateg
2012).
F
Produc
softwar
process
3.1.2 To defi
Thepro
Plann
ONCEPThapterexpl
f the chapt
ollowed by
ecturedefin
CONCEPT are twom
edandtheo
GENERAL Mneral appr
gy (Figure
Figure8:Ge
ctionramp
re definitio
s.
MODULAR ine themo
ocessisdiv
F
ing
Review
T DEVElainsthepr
ter follows
y the conce
nition.
DEVELOPMmethodswh
otheristhe
METHODOLroach to th
8) defined
enericProd
upisnoti
on are enc
ARCHITECTodular arch
videdintos
Figure9:Vo
ConceptDevelopment
w
ELOPMErocessofc
s a uniform
ept genera
MENT METhich are ap
emodulard
LOGY heoverall p
d in Produ
ductDevelo
includedin
ompassed
TURE DEFINhitecture, V
sixstepswh
olvoCEMod
SysteDe
Review
12
ENT conceptdev
m structure
ation, conc
THODOLOGpplied in th
designpro
project foll
ct Design
opmentPro
nthescope
into the ab
NITION PROVolvo’s inte
hichisshow
dularisation
emLevelesign
Revie
velopment
ewhere th
ept evalua
GY his project.
cessofVCE
lows the ge
and Devel
ocess(Ulric
eofthepro
bovement
OCESS ernalmeth
wnbelow.
nmethod(S
DetailDesi
ew
fromther
hemethodo
ation endin
. One is th
E.
enericprod
opment (U
chandEppi
oject.Both
tionedprod
hodology (F
Source:VCE
ign Tre
Review
requiremen
ology is di
ng in the p
he generic
ductdevel
Ulrich & Ep
inger,2012
thehardw
duct devel
Figure 9)
E)
Testingandrefinement
Rev
nts.The
scussed
product
process
opment
ppinger
2)
areand
opment
is used.
ProducRamp
view
ctionp‐Up
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13
Step 1: Define Scope Scopedefinitionplaysanimportantroleindeterminingthecomplexityofthemodules.
Itisimportanttomakeaconsciouschoiceonwhattoincludeandwhatnottoinclude.
Asthisprojectservesasaprestudyforfutureproducts,modulesarelimitedtotheirtop
levelonly.
Step 2: Stakeholder needs Theneedsofallthestakeholdersneedstobecaptured.Stakeholdersmaybeadvanced
engineering, operations, technology platform, product design, product platform,
productplanning,purchasing,etc.Theproductsentire lifecycleneedstobetakeninto
account and the synergies needs to be identified. It is necessary to create a balance
betweentheneedssothatanoptimumarchitecturecanbedesigned.Sincetheproject
serves as a prestudy the main stakeholder would be the designers of the current
productcategoriesandtheexistingdesign.
Step 3: Requirements Theneedsgivenby thedifferentstakeholdershavebeenexpressed indifferentways.
Thesehave tobe converted into a common technical specificationwith requirements
thatcanbeunderstoodbytheengineers.Requirementscaneitherbefunctional,logical,
physicaloracombinationoftheabovethree.
Step 4: Visualization of technical solutions This is the first step to create the product architecture and hence identifying the
modules and interfaces. This is mainly done so that none of the requirements are
forgotten.Conceptsketchesarecreatedwithoutmuchdetailsinthisstep.
Step 5: Finding the Modules Thekeytomodularityistofindpatternscrossaproductrange.Patternsshowuswhat
canbecommonandwhathastobeuniqueforeachvariant.Thesolutionistoidentify
commonaswellasuniquerequirements.Thisinvolvesthreesteps
Identifyingcommonsolutions
Identifyinguniquesolutions
Identifyingperformancesteps
Step 6: Business Case Verification Thisstepwillhelpinveryfyingthebusinesscaseandansweringcertainquestionslike
Doestheproductmeetthecosttargets?
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14
Doesthearchitecturemeettherequirementsoftheproducts?
Isthemodulardesigncheaperthantheintegraldesign?
Whatistheeffectonweight,qualityandproductivity?
3.2 CONCEPT GENERATION Conceptgenerationisanimportantstepintheproductdevelopmentprocesswherethe
various inputs collected fromdifferent stakeholders are converted intoamoreuseful
product(Ulrich&Eppinger2012).
3.2.1 SHAPE DRIVERS In order to identify the dimensional constraints of design, a studywas conducted to
identifydifferentfactorswhichaffecttheshapeofahood.Eventhoughtheshapeofthe
hoodisdrivenbystyling,engineeringconstraintstoodrivetheshapeofthehood.The
concept behind zone definitions is based on the limits up to which a cluster of
componentsdrivethedesignofthepanel.Forexample, inWheelLoaders, thecooling
package drives the size of the panels in and around the radiator grille but has no
significant impact on the design of the panels surrounding the engine. This helps to
seperate the engine bay into different zones. Constraints from all directions to the
dimensionsofthehoodareanalyzedinordertoefficientlycomparebetweendifferent
productcategories.
Wheel Loader TheshapeofaWheelLoaderhoodismoreofa“beanbagshape”whenviewedfromthe
top.Thishasanegativeeffectontheeasewithwhichitcanbemodularized.
Wheel Loader Zone Definition
Inordertodefinethedimensionalconstraintsatdifferentpartsofthehood,theentire
hoodisdividedintodifferentzonesasshowninFigure10andFigure11.Thevarious
dimensional constraints for different zones are summarized inTable3 for theWheel
Loaders.
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Table3
Zones
Zone1
Zone2
Zone3
ObservaSomeo
Figur
3:Summary
Descrip
Areabethefend
Areaartheaftetreatme
Areaarcoolingsystem
ations oftheobser
WheelLoa
5006andv
The length
effecton t
rearaxle i
maneuveri
re10:Whee
Figure11
y‐ZoneDef
ption C‐
eneathder
WE
rounderent
VCw
roundg
V
rvationsfro
adersareco
visibilityto
hof theho
the turning
soneofth
ingtheveh
elLoaderT
1:CompactW
finiton–Wh
onstraintsExterior
Wheelnvelope
isibilityofounterweights
isibility
omTable3
onstrained
owardsthe
odcannot
g radius.Th
hemainun
hicleeasily
15
opView(L
WheelLoad
heelLoade
s Constr‐Interi
Engine
Exhaustreatmesystem
Coolingpackag
arelisted
dmainlyby
counterwe
be increas
hedistance
niquesellin
eft)ZoneD
der–Zone
rs
aintsior
Ca
Noen
tent
Nosys
ge
Nopa
below
yvisibility
eights
sedbecaus
ebetween
ngpoints(U
Definition(R
Definition
anbechang
o–Gapbetwvelopeism
o–Gapbetwstemandth
o–Gapbetwckageand
regulations
eofoverha
thecounte
USP)forVC
Right)
ged?
weenthewminimum
weentheehehoodis
weenthechoodismi
sgoverned
ang issues
erweights
CEwhichh
wheel
exhaustoptimum
oolingnimum
dbyISO
and its
and the
helps in
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Soil ComSoilCom
Anadd
alongw
dueto
the1m
isthele
Soil ComThe zo
Table4
mpactors mpactorsh
ditionalvibr
withtheop
thesteep
mX1mvisib
egalrequir
mpactors Zone definiti
4.
haveauniq
rationalloa
perationall
inclination
bilityrequi
rement).
Figur
one Definitiion of Soil
Figure
quedesign
adof45HZ
oad.Thera
nofthehoo
irement(se
e12:SoilC
ion Compacto
e13:SoilCo
16
whencom
Zisencount
adiatorsar
od.Theste
eeFigure1
Compactors
rs is descr
ompactors
paredtoth
teredbyth
representa
eepinclinat
12)whichi
s–Visibility
ribed in Fig
–ZoneDefi
heotherve
hecompone
ataninclin
tionofthe
isanUSPo
yZone
gure 13 an
inition
ehicleswith
entsofthe
nedangle,w
hoodisto
ofVCE(1m
nd summar
hinVCE.
vehicle
whichis
osatisfy
X1.5m
rized in
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Table4
Zones
Zone1
Zone2
Zone3
Observa
ArticulaArticula
visibilit
top pan
compar
ArticulaThezon
Table5
4:Summary
Descrip
Areabeneathfender
Areaartheairintake
Areaarcoolingsystem
ations
The design
constraine
Theabsen
similartoa
ated Haulerated Haule
tyandgrou
nel is smo
redtothet
ated Haulernedefinitio
5.
y‐ZoneDef
ption CoEx
htheWEn
round ViUS1m
roundg
ViUS1m
n is driven
edbytheUS
nceof thee
anArticula
rs ers are cha
undclearan
oth due to
toppaneld
Zone DefinonofArticu
Figure1
finiton–So
onstraintsxterior
Wheelnvelope
isibility,SPof1mXm
isibility,SPof1mXm
nmostly by
SPrequirem
exhaust sys
atedHauler
aracterized
nce.Theco
o the absen
designofSo
nition ulatedHau
14:Articula
17
oilCompact
‐ Constr‐Inter
Engine
AirIntsystem
Coolinpackag
y the USP
ment.
stemon th
r
d by their u
oolingfans
nce of the
oilCompact
ulersisdesc
atedHauler
tors
raintsrior
C
e Nwm
takem
YsU
ngge
YsU
of 1m X 1
he topgive
unique slim
areonthe
engine inl
tors.
cribedinF
rs‐Zonede
Canbecha
No–Gapbewheelenvelminimum
Yes–IfcosubstantialUSP
Yes–IfcosubstantialUSP
m. The ent
sa rather
mwaist de
sidestosu
lets and ex
Figure14an
efinition
anged?
etweenthelopeis
stbenefitiscompared
stbenefitiscompared
ntire engine
smooth to
esign tom
uitthisdesi
xhausts. It
ndsumma
to
to
e bay is
ppanel
aximize
ign.The
can be
rizedin
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18
Table5:Summary‐ZoneDefiniton‐ArticulatedHaulers
Zones Description Constraints‐Exterior
Constraints‐Interior
Canbechanged?
Zone1 Areabeneaththeengine
WheelEnvelope
Engine Yes‐Topofhoodcanbemodifiedasitiselevatedforflushfitwithcab
Zone2 Areaaroundtheradiator
Visibility Coolingsystem
No‐Widthcannotbeincreasedduetovisibilityrequirements
Zone3 Areaaroundradiator
Visibility Coolingsystem
No‐Widthcannotbeincreasedduetovisibilityrequirements
Observations
Heightofthehoodcanbealteredduetothefactthatthetopsillsareelevatedto
matchwiththecabswidthandcanbemodifiedtosuitthemodularrequirements
Widthofthehoodcannotbeincreasedcomparedtothecurrentdesignasitmay
decreasethevisibilityandviolatelegalrequirements
Motor Grader ThehoodofMotorGraderswhich is taken into the study consists of only the frontal
portion of the entire hood. The reason for not considering themiddle section of the
hoodisduetothefactthatthemiddlesectionrequiresgullwingtypedoorstoaccess
theenginebaywhereastheradiatorrequiresahingedooropeningawayfromthecab.
This isdue to the fact that themiddle sectionof theenginebayneeds tobeaccessed
fromthesides.
Motor Grader Zone Definition Sincethedesignofthefrontsectionofthehoodisdependentontheradiator,theentire
zonedefinition is limited toone.ThezonedefinitionofMotorGraders isdescribed in
Figure15andsummarizedinTable6.
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Table6
Zones
Zone1
Observa
BackhoThedim
rolein
otherfa
BackhoThe zo
Table7
6:Summary
Descrip
AreabeneathRadiato
ations
Thewidth
andinterfe
negativeef
Thesidepa
compared
oe Loader mensionof
thedesign
actorswhic
e Loader Zonedefiniti
7.
Figur
y‐ZoneDef
ption CoEx
htheor
ViAr
ofthehood
erencewith
ffectonvis
anelshave
withaWh
f thehood
noftheBac
chaffectsth
one DefinitionofBack
re15:Moto
finiton–Mo
onstraintsxterior
isibility,rmtravel
dcannotbe
hthearmtr
ibility
grillmesh
eelLoader
isconstrai
ckhoeLoad
hedesign.
on khoeLoade
19
orGrader‐
otorGrader
‐ Constr‐Inter
Radiat
eincreased
ravel.Theh
coveringm
sidepanel
inedbyth
derhood.V
ers isdescr
ZoneDefin
rs
raintsrior
C
tor Noaa
dduetothe
heightcann
morethan8
earmsof t
Visibilityan
ribed inFi
nition
Canbecha
No–Dimenoptimizedbanddimensandarm.
enegativee
notbeincre
80%ofthe
thebooma
ndsizeoft
gure16an
anged?
nsionsarebetweenvissionsofrad
effectonvi
easeddue
area.This
andplaysa
theengine
nd summar
sibilitydiator
isibility
tothe
canbe
amajor
arethe
rized in
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Table7
Zones
Zone1
Zone2
Observa
3.2.2 Theba
noted d
dimens
7:Summary
Descrip
Areaartheengandrad
Areaartheengandtheexhausttreatmesystem
ations
Thewidth
andinterfe
negativeef
Thesidepa
withtheto
DIMENSIONasic functio
down to id
sions are th
Figure
y–ZoneDe
ption CoEx
roundginediator
BoVi
roundgineetent
BoVi
ofthehood
erencewith
ffectonvis
anelsandt
oppanelof
N ANALYSISonaldimen
dentify any
hen compa
e16:Backh
finitionBac
onstraintsxterior
oomArm,sibility
oomArm,sibility
dcannotbe
hthearmtr
ibility
toppanelsh
SoilCompa
S sionswhic
y dimension
aredwith e
20
hoeLoader
ckhoeLoad
‐ Constr‐Inter
Engineradiato
Enginetheexhtreatmsystem
eincreased
ravel.Theh
havenoop
actorsand
chdefine th
nal synerg
eachother
‐ZoneDefi
der
raintsrior
C
eandor
Nhwaw
eandhaustmentm
Nhwaw
dduetothe
heightcann
penings.Th
Articulated
hehoodsa
gies thatm
inorder t
inition
Canbechan
No–Widthhingeisfixewouldhaveandincreaswouldaffec
No–Widthhingeisfixewouldhaveandincreaswouldaffec
enegativee
notbeincre
etoppanel
dHaulers
aremeasur
ay exist be
to identify
nged?
ofboomared.Anychaearippleefeinheightctvisibility
ofboomared.Anychaearippleefeinheightctvisibility
effectonvi
easeddue
lcanbecom
red fromC
etween the
smalldim
rmangesffectt
rmangesffectt
isibility
tothe
mpared
ADand
em. The
ensions
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whichc
for all
dimens
Wheel LTheWh
dimens
Thevie
isthel
canbeneg
the mode
sionswhich
Loader heel Loade
sionswhich
a‐Widthn
b‐Widthn
c‐Overall
d‐Distanc
e‐Heighto
f‐Heighto
g‐Overall
h‐Heighto
Figur
Fi
ewonthel
efthandsi
gatedtodef
els in the
hdrivethe
ers hoodh
haretaken
neartherad
neartheen
lengthinm
cebetween
ofthehood
ofthehood
heightoft
oftherears
e17:Drivin
igure18:D
eftsideist
ideviewof
finecommo
study. Th
shapeofth
as eight di
nintoaccou
diatorinm
ngineinmm
mm
rearenda
dneargrille
nearengin
hehoodin
sectionoft
ngDimensi
DrivingDim
thetopview
fthehood
21
onmodule
he dimensi
hehood.
ifferentdim
untareliste
mm
m
andexhaust
efrombase
nefrombas
mm
thehoodin
ions–Gene
mensions–C
woftheW
(Figure17
s.Thedime
ons are li
mensionsw
edbelow
topening(
eplaneinm
seplanein
nmm
eralPurpos
CompactWh
WheelLoade
7andFigur
ensionalco
imited only
which cont
(min)inmm
mm
mm
eWheelLo
heelLoade
erhoodand
re18).The
omparison
y to a few
trol its sha
m
oaders
ers
dontherig
ebaseplan
isdone
w basic
ape. The
ghtside
einthe
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dimens
conditi
Table8
L60H
L110H
L150H
L220H
Table9
L20F
L30G
L45G
A bar
dimens
betwee
Fig
sions refer
on.Thedim
8:DrivingD
a
1220
1550
1680
1680
9:DrivingD
a
1380
1420
1600
graph (Fig
sionshelps
enthedesig
gure19:Com
rs to the p
mensionso
Dimensions
b
1060
1280
1280
1280
Dimensions
b
1420
1310
1530
gure 19, Fi
tovisualiz
gnscanbe
mparison–
plane on w
oftheWhee
–GeneralP
c
1915
2625
2740
2905
–Compact
c
1035
1080
1600
igure 20, F
zethenumb
easilyiden
Topviewd
22
which the h
elLoadersa
PurposeW
d
720
800
650
820
tWheelLoa
d
400
320
400
Figure 21
bersinam
ntifiedusing
dimensions
hood rests
aresumma
WheelLoade
e
980
1000
1145
1145
ader
e
440
590
580
and Figure
moremeani
gthegraph
sofGenera
on the fr
arizedinTa
er
f
1360
1270
1555
1555
Alldime
f
620
560
930
Alldime
e 22) show
ngfulmann
h.
lPurposeW
rame at its
able8andT
g h
1430
1525
1735
1735
ensionsare
g
630
630
930
ensionsare
wing the d
ner.Thesy
WheelLoad
s closed
Table9.
h
500
465
590
590
einmm
h
550
410
410
einmm
different
ynergies
ders
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Figuure20:Com
Figure21
Figure22:
mparison–
:Comparis
:Compariso
Sideviewd
on–Topvi
on–Sidevi
23
dimensions
iewdimens
iewdimens
sofGenera
sionsofCom
sionsofCom
alPurposeW
mpactWhee
mpactWhe
WheelLoad
elLoaders
eelLoaders
ders
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Inferenarchitec
440and580
ces from Wcture.
GeneralPu
Thewidth
Figure 23)
heightoft
architectur
theheight
commoniz
Compact W
Theoveral
therearse
becommo
0mmd0mm
Wheel Loade
urposeWhe
oftherea
), resulting
thefrontgr
re).Thehe
oftherear
edbetween
Fig
Wheel Loade
llheight(e)
ectionheigh
nizedbetw
Figu
er graphs ex
eelLoaders
rsection(b
g in two pe
rille(e)has
eightiscom
rsection(h
nthemode
gure23:Inf
ers
)ofthefron
ht(h)ofthe
weenthetw
ure24:Infe
24
xplain the in
s
b)iscomm
erformance
stwoperfo
mmonforL
h)hastwo
elsduetoth
ference‐W
ntgrilleha
ehood(see
wovariants
erence‐Com
1050
100
nferences lin
monforL12
e steps on
ormancest
L60H‐L12
performan
heseperfor
WheelLoade
astwoperfo
eFigure24
.
mpactWhe
0mmand1
0mmand1
nking it to t
20H,L150H
the rearw
teps(taken
20HandL1
ncesteps.S
rmanceste
ers
ormancest
4).Asaresu
eelLoaders
1280mm
1145mm
500mm
the final pro
HandL22
width. The
ncarebyth
150H‐L22
Sidepanels
eps.
tepsalongw
ultsidepan
s
mand590m
410mand550m
oduct
0H(see
overall
hegrille
20Hand
scanbe
with
nelscan
mm
mm
mm
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Soil ComSimilar
definet
Theval
Table1
SD25 SD45 SD70 SD75 SD115 SD160
A bar
visualiz
canbe
mpactors rtoWheel
thebounda
a‐Widthn
b‐Widthn
c‐Overall
d‐Distanc
e‐Heighto
f‐Heighto
g‐Overall
h‐Heighto
luesofthe
10:Driving
a 690 710 970 1175 1180 1100
graph (Fig
zethenum
easilyiden
Loaders,S
ariesofthe
neartherad
neartheen
lengthinm
cebetween
ofthehood
ofthehood
heightoft
oftherear
dimension
Figure2
Dimension
b 865 910 1300 1430 1420 1485
gure 26 an
mbersinam
ntifiedusing
oilCompac
ehood.The
diatorinm
ngineinmm
mm
rearenda
dneargrille
nearengin
hehoodin
sectionoft
saresumm
25:Driving
ns‐SoilCom
c 920
1260
2020
1715
2235
2300
nd Figure
moremeani
gthegraph
25
ctorsalsoh
elistofdriv
mm
m
andairinta
efrombase
nefrombas
mm
thehoodin
marizedin
Dimension
mpactors
d
60
210
380
790
380
540
27) show
ingfulmann
h.
haveeight
vingdimens
keopening
eplaneinm
seplanein
nmm
Table10.
ns–SoilCom
e
650
700
50
125
160
0
wing the di
ner.Thesy
dimension
sionsisme
g(min)inm
mm
mm
mpactors
f
850
890
930
1000
1040
920
Alldime
ifferent dim
ynergiesbe
ns(Figure2
entionedbe
mm
g 850 890 930 1000 1040 920
ensionsare
mensions
etweenthe
25)that
elow
h
685
890
890
880
750
880
einmm
help to
designs
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InferenThefro
thehoo
broken
1715mm
Figure
Figure
ces ontwidth(
od(c)varie
ndownand
mand1235
e26:Comp
e27:Comp
a)andrear
esintwost
dcommoniz
Figu
5mm
arison–To
arison–Sid
rwidth(b)
teps(seeF
zedbetwee
ure28:Infe
26
opviewdim
deviewdim
)ofSD75a
Figure28).
enmodels.
erences‐So
mensionsof
mensionsof
ndSD115i
Asaresult
oilCompact
1
1
fSoilComp
fSoilComp
isthesame
tsectionso
tors
1175mm
420mm
pactors
pactors
eandthele
ofthehood
engthof
dcanbe
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ArticulaDueto
limited
describ
Theval
Table1
A20F
A40F
Abarg
in a m
identifi
ated Haulertheabsenc
d to five i
bedbelow
a‐Widthn
b‐Widthn
c‐Overall
d‐Height
e‐Heighto
luesofthe
11:Driving
graph(Figu
more mean
iedusingth
r ceofinleto
n an Artic
nearthefro
neartheen
lengthinm
ofthehood
oftherear
dimension
Figure29
Dimension
a
2150
1950
ure30)show
ningful ma
hegraph.
orexhaust
culated Ha
ontinmm
ngineinmm
mm
dneargrille
sectionoft
saresumm
:DrivingDi
ns‐Articula
b
2520
2720
wingthed
nner. The
27
featureso
auler. The
m
efrombase
thehoodin
marizedin
imensions
atedHailers
c
16
19
ifferentdim
synergies
nthehood
driving d
einmm
nmm
Table11.
‐Articulate
s
650
960
mensionsh
s between
d,thedrivin
dimensions
edHaulers
d
680
720
Alldime
helptovisu
the desig
ngdimensi
s (Figure 2
e
1080
1450
ensionsare
ualizethen
gns can be
ionsare
29) are
0
0
einmm
umbers
e easily
![Page 42: Mo nd D tion of ce - Chalmers Publication Library …publications.lib.chalmers.se/records/fulltext/218250/...Depart CHALM Gothen Mo Con Das Pla Master MUR ment of Pr ERS UNI burg,](https://reader033.vdocuments.us/reader033/viewer/2022041616/5e3b6fddb176726c3812810c/html5/thumbnails/42.jpg)
InferenThehe
otherc
betwee
Motor GThenu
five di
conside
Theval
Figure
nceseightof the
commonalit
enthemod
Grader umberofdi
mensions
ered.Thed
a‐Widthn
b‐Widthn
c‐Overall
d‐Height
e‐Heighto
luesofthe
700mm
30:Compa
e frontgrill
tycanbeo
els.
Figur
imensiond
due to th
dimensions
nearthefro
neartheen
lengthinm
ofthehood
oftherear
dimension
arison–Dri
le is comm
observedb
re31:Infer
drivers(Fig
e fact tha
considered
ontinmm
ngineinmm
mm
dneargrille
sectionoft
saresumm
28
ivingdimen
monbetwee
etweenthe
ences‐Arti
gure32)in
at only the
darelisted
m
efrombase
thehoodin
marizedin
nsionsofAr
en the two
etwomod
iculatedHa
thecaseo
e front sec
dbelow
einmm
nmm
Table12.
rticulatedH
models (s
elsinany
aulers
fMotorGra
ction of th
Haulers
seeFigure
ofthedim
adersislim
he entire h
31).No
ensions
mitedto
hood is
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Table1
G930C
G940C
Abarg
in a m
identifi
InferenAllthe
differen
12:Driving
graph(Figu
more mean
iedusingth
Figu
ces maindrivi
ntpanelsc
Figure3
Dimension
a
1020
1020
ure33)show
ningful ma
hegraph.
ure33:Com
ingdimens
anbecomm
32:Driving
ns–MotorG
b
1020
1020
wingthed
nner. The
mparison–
sionsexcep
monizedac
29
gDimension
Graders
0
0
ifferentdim
synergies
Drivingdim
ptthelengt
ccordingly.
ns–Motor
c
980
1110
mensionsh
s between
mensionso
thoftheho
Graders
d
700
700
Alldime
helptovisu
the desig
fMotorGra
oodarethe
e
1
1
ensionsare
ualizethen
gns can be
ader
esame.As
180
180
einmm
umbers
e easily
aresult
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BackhoAllBac
listedb
Theval
Table1
BHL
Abarg
in a m
identifi
oe Loader ckhoeLoad
below
a‐Widthn
b‐Widthn
c‐Overall
d‐Distanc
e‐Heighto
f‐Heighto
g‐Overall
h‐Heighto
luesofthe
13:Driving
a
740
graph(Figu
more mean
iedusingth
dershaveth
neartherad
neartheen
lengthinm
cebetween
ofthehood
ofthehood
heightoft
oftherears
dimension
Figure34
Dimension
b
760
ure35)show
ningful ma
hegraph.
hesameho
diatorinm
ngineinmm
mm
rearenda
dneargrille
nearengin
hehoodin
sectionoft
saresumm
4:DrivingD
ns–Backho
c
1610
wingthed
nner. The
30
oods,theb
mm
m
andexhaust
efrombase
nefrombas
mm
thehoodin
marizedin
Dimensions
oeLoaders
d
210
ifferentdim
synergies
basicdrivin
topening(
eplaneinm
seplanein
nmm
Table13.
s–Backhoe
e
500
mensionsh
s between
ngdimensio
(min)inmm
mm
mm
eLoaders
f
900
Alldime
helptovisu
the desig
ons(Figur
m
g
960
ensionsare
ualizethen
gns can be
e34)is
h
100
einmm
umbers
e easily
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InferenSinceth
differen
panelo
change
instead
Grille DThegri
maind
Theval
Figur
ces hehoodis
ntconstrai
ofBackhoe
eindesign
dofamodu
Dimensions illeplaysa
imensions
Fig
a‐Widtho
b‐Widtho
c‐Overall
d‐Widtho
luesofthe
re35:Comp
alreadyco
ints, thestu
Loadersca
wouldincr
ulardesign.
nimportan
(Figure36
gure36:Co
ofhoodinm
offrontme
heightofh
offinsinm
dimension
parison–Dr
mmonfor
udy is limi
anbecomp
reasethep
.
ntroleinp
6)whichare
mparison–
mm
shinmm
hooduptoh
m
saresumm
31
rivingdime
alltheBac
ited to the
paredtoth
partnumbe
portraying
etakenint
–Drivingdi
headlampl
marizedin
ensionsofB
ckhoeLoad
commoniz
hetoppane
er.Theinte
thedesign
oconsidera
imensionso
levelinmm
Table14
BackhoeLo
ermodels
zationofpa
elofSoilCo
egraldesig
languageo
ationissho
ofFrontGr
m
oaders
andoptim
artsonly.T
ompactors
gncanber
ofVolvo.T
ownbelow
rille
izedfor
The top
butthe
retained
Thefour
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Table1
L20F
L30G
L45G
L60H
L110H
L150H
L220H
A20F
A40F
G930C
G940C
Abarg
in a m
identifi
14:Driving
graph(Figu
more mean
iedusingth
Fig
Dimension
a
1380
1420
1600
1090
1410
1580
1580
1120
1120
1020
1020
ure37)show
ningful ma
hegraph.
gure37:Co
ns–FrontG
wingthed
nner. The
mparison–
32
Grille
b
820
1020
1020
860
1210
1220
1220
1120
1120
700
700
ifferentdim
synergies
–Drivingdi
c
440
590
580
970
920
105
105
680
720
100
100
mensionsh
s between
imensionso
0
0
0
0
0
50
50
0
0
00
00
Alldime
helptovisu
the desig
ofFrontGr
D
130
160
130
160
175
180
180
180
180
180
180
ensionsare
ualizethen
gns can be
rille
einmm
umbers
e easily
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Inferen
3.2.3 Oneof
Knowle
project
effectiv
3.2.3.1 Interna
Modula
modula
inorde
nces
Thedistan
allmodels
Thewidth
38)
Thewidth
Thiscanhe
satisfythe
BENCHMARthebestw
edgehasbe
ts.Thelear
velyreducin
INTERNalbenchma
arCab(See
ararchitect
ertoallowp
ncebetween
duetothe
ofthemes
ofthemes
elpincomm
width(a)r
RKING waystoimp
eengathere
rningsfrom
ngresourc
NAL BENCHMarkinghelp
eFigure39)
tureofthe
possiblein
nthefins(d
sizeofthe
h(b)iscom
hes(b)ism
monizingth
requiremen
Figure38
proviseorf
edinanorg
mdifferentp
esandtime
MARKINGstoidentif
)definition
hood.Diffe
terchange
33
d)inthem
Volvologo
mmonforL
morecomm
hewidthof
nts
8:Inference
findsolutio
ganization
projectsca
etakentot
fysolutions
nwasoneo
erentmodu
andreuseo
meshesfollo
o(seeFigur
L120H,L15
monthanth
fthemeshe
es‐Grille
onstoprob
overaper
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CA
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ATEGORY
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Table1
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Figure554:Product
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48
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4.2.1 TheCo
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50
4.2.3 FEATURES OF THE VARIANT MANAGEMENT MODULE SomeofthesalientfeaturesoftheVariantmanagementmodulearedescribedbelow
Roles Access to the different parts of themodule can be restricted based on different user
roles.Forexample,accesscanbegiventotheproductengineertocreatenewproducts
based on predefined rules but no access is given to create a new configuration by
breakingtherules.Productmanagercanbegivenaccesstobreaktherulesandcreate
newproductconfigurations.
Version Management and Traceability Changes in the features and options can be captured as revisions, as a result the
evolution of the configuration features andoptions canbe visualized easily using the
Variantmanagementmodule.
Theability toallocatetherequirements tovariousentities likeconfiguration features,
configuration options, physical models etc. enables the ease of traceability.
Requirementsandproductswhicharerelatedtothevariousconfigurationfeaturesand
optionscanbeeasilytraced.
Effectivity Date effectivities can be allocated to various features and options. For example, if a
specificrequirementarisesforvibration,say“VibrationRequirementfor70HZisvalid
fromJanuary1st2015”onSoilCompactors,Configurationfeaturesandoptionsrelated
to the new vibration requirement are assigned date effectivities which result in the
optionsnotbeingvisibleonDec31st2014butvisibleontheJan1st2015.
4.2.4 EXAMPLE OF CONFIGURATION FEATURES AND OPTIONS ‐ MODULAR HOOD DESIGN
Anexampleoftheconfigurationfeaturesandoptionsforthemodularhoodisshownin
Figure 60. The column display name shows the list of configuration features and
options.Thecolumnsingular/multiplestatesthatwhethertheoptionsselectioncanbe
singular(onlyoneoptioncanbeselected)ormultiple(manyoptionscanbeselected).
The entire features can be sequenced which controls the order of options when
selecting the product configuration. The date effectivities control the timelinewithin
whichtheoptionsarevalid.Thisresultsinasetofoptionsbeenshownononedayanda
completelynewsetofoptionsanotherday.ThecompletelistofConfigurationfeatures
andoptionsarelistedintheAppendixIII.
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4.2.5 Configu
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When
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Figure
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Thesum
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Step 1:
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Step 2:
feature
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Date ef
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Sinceth
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57
5. MANUFACTURING METHODS This chapter explains about the challenges inmodular design of products, design for
assemblyandpossiblemethodsforassemblyofthemodularcomponentswhichhelps
torealizethemodulardesignofthehood.
5.1 MODULAR DESIGN ‐ CHALLENGES IN MANUFACTURING Modularsolutionsmaysometimesrequireadditionalassemblyoperationstorealizethe
design. This poses challenges with respect to logistics, inventory, manufacturing
methods,etc.Thegapsandflushrequirementsonthematingpartsmayposechallenges
onhowthemodularsolutionismanufactured.
Apartfromtheabovechallenges,questionsonwhetherthepartshouldbeassembledat
the suppliersendor inside theplant in subassembly linesneeds tobe researched in
order to take a decision onwhere to assemble the product. In the quest to improve
better reusability of panels, individual panels may be broken down resulting in
increasednumber of split lines. The ability to provide amodular solutionwhich also
appealsaestheticallyisachallengeduetotheincreaseinthenumberofsplitlines.
Advantages of breaking down the components can be smaller tools and thereby
reducingtheoverallcostofthecomponents.Anotheradvantageofhavingthemodules
manufacturedbythesupplierishigherspeedofproductionandreducedcosts(Wits&
Vaneker2011).
Supply chain too has a role to play in the modular design of components. The
relationshipbetweentheOEMandthesupplierplaysanimportantroleinthedesignof
components(Ülkü&Schmidt2011).Modulardesignrequireslessinvestmentintooling
andinfrastructurecomparedtointegraldesign.
5.2 DESIGN FOR ASSEMBLY Designforassemblyisamethodwheretheaspectsofassemblyareconsideredfromthe
early stages of design. Studies reveal that enormousbenefits such as lower assembly
and manufacturing costs, improved quality, reduced time to market, etc. can be
achieved through this method. (Boothroyd & Alting 1992). Challenges posed by the
assemblyprocessareidentifiedinthestartofthedesignstageitselfthroughinterviews
with experts, benchmarking etc. Some of the proposals to solve this problem are
describedbelow.
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5.2.1 Basedo
ordert
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INTERFAThepan
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InterfacSimple
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FASTENOnceth
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6. DISCUSSION Thischapterprovidesareflectionandcriticalthinkingofthedifferentsectionsinthereport.
6.1 DISCUSSION ON NEEDS MAPPING Capturing the requirements from two different perspectives helped to cover the
requirementsofthehoodinaholisticmanner.Distinguishingtherequirementcapture
methods into the genericmethod helped to analyze the problem and decompose the
hood with respect to the design requirements, whereas the functional perspective
helpedtoidentifytherelationshipbetweenthefeaturesofthehoodandits impacton
designwhichwaseffectivelyusedintheconfigurationfeatureandoptiondefinitionin
the3DXplatform.
Oneofthemaindrivingfactorsforbreakingdownthehoodintofivedifferentsegments
was the need to satisfy different stakeholders’ needs with a common solution. The
interfaceanalysishelpedtounderstandtheunderlyingrelationshipbetweentheparts
of the hoods and its surrounding components but it was not implemented in the
documentationofthetechnicalsolutionas the interrelationshipbetweenthedifferent
surrounding components and the hood design needed to be defined. Due to the
explorativenatureofthestudy,thiswasnotconsideredinthetechnicaldocumentation.
6.2 DISCUSSION ON THE CONCEPT DEVELOPMENT Theconceptdevelopmentstudyfollowedasystematicbreakdownofthehoodbasedon
its functions fordifferentproduct categoriesandalsocomparing thembasedon their
shapesanddimensionalconstraints.Volvo’sinternalmethodusedformodularproduct
development along with the generic product development methodology helped in
approaching the problem in a structuredmanner. TheModular cabwas an excellent
exampleofhowaproductisbrokendownbasedonitsfunctions.Lotsofsynergieswere
foundwithinandbetweenproductcategories.Thestudywaslimitedconsciouslytothe
toplevelassemblyduetoitsexplorativenature.
Constraintswith respect to the exterior dimensionswere strictly adhered to, so that
there isnoviolationofvisibility regulations.Theconstraintsput forthby theexisting
componentsareretainedsothattheproposedtechnicalsolutioncanbeeasilyrealized
withoutaffectingthedesignofthesurroundingcomponents.Thestudyeventhoughis
elaborate on the top level is not complete without studying the effects on the
surroundingcomponentstoo.Moreresearchneedstobecarriedoutinthisarea.
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Themethodofoptimizationusedtofindthe leastnumberofcommonpartshelpedto
reduce the number of parts required to satisfy the requirements of differentmodels.
Researchneedstobecarriedouttofindoutifanymathematicalmethodisavailableto
reducethenumbersfurther.
Tradeoff’smadebetweentheUSP’sandthedesignconstraintsplayanimportantrolein
implementing amodular solution.Defining the architecture of the engine bay and its
relationshipwith respect to the cab and axle plays an important role in defining the
designboundariesofthehoodinalltheproductcategories.
Themethodusedforvisualizingthedimensionsusingbarchartswassimpleandvery
effective to identify the synergies in design. The impact of trading off the USP of
visibilityrequirementsinSoilCompactorswithrespecttothemodulardesignneedsto
be studied. From the preliminary studies, the scope of changing the visibility
requirementsfrom1mX1mto1mX1.5mhelpsinpanel’sreusabilityonthetwosides.It
also helps to organize the engine bay thereby commonizing the alignment of the
radiatorandthecoolingsystem.
6.3 DISCUSSION ON THE TECHNICAL DOCUMENTATION Various featuresof the3DXplatformwereeffectivelyused todocument the technical
solutions.Theimplementationoftheconfigurationfeatures,configurationoptionsand
the rules were simple straightforward tasks. The training provided on the different
modulesalongwith theonlinehelp (Documentation) strengthened theunderstanding
ofthesoftwareandeasedtheuseofthesoftware.The3Dconfiguratorwhichshowsa
real‐time light weight model made the product configuration creation process more
intuitive. The seamless integration between the web and CAD interface reduced the
timetakentoconfiguretheproducts,i.e.whenanewconfigurationoptioniscreatedin
thewebinterfaceitisimmediatelyvisibleintheCADinterface.
The open nature of the software posed a different challenge due to the wide scope
available to document the solutions (Documentation can be done with multiple
methods). Themethods chosen for documentationweremainly oriented towards the
interests of the productmanagers anddesigners. Thedocumentation of the technical
solutions does not capture any manufacturing related documentations which can be
carriedoutinthefuture.
The ability of the software to collaborate with different people at the same time
improvestheoverallefficiencyoftheproductdevelopmentprocess.Researchsuggests
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thatsupplychaincollaborationhasenabledcompanies tocompetemoreefficiently in
themarket by improving design quality, enabling reuse, lowering product costs, etc.
(Bankeretal.2006)
6.4 DISCUSSION ON THE MANUFACTURING METHODS Manufacturing assemblyprocess feasibility studyplays an important role in realizing
theproposedtechnicalsolutions.Oneofthemainindicatorsofthesuccessofaconcept
liesintheeasewithwhichitcanbecommercialized.Thedesignforassemblyconcepts
providesastrongbaseinprovidinganeffectiveandefficientsolutionfortheinterfaces.
Theproposedassemblymethodsdescribethedesignoftheinterfacesofthepanelsand
thegrilleinasimpleandeffectivemanner.
The advantages and disadvantages of having amodular solution are described in the
manufacturingsectionclearlyhighlightingeffectsonlogistics,inventory,manufacturing
methodetc.Theproposal for themanufacturingmethod is rudimentaryona concept
levelwhichneedstobefurtherstudiedupon.Theattachmentmethodproposedforthe
grillefollowsaunique“Legoblocklike”designwhicheffectivelyreducesthenumberof
components.Costanalysisofthetoolingneedstobecarriedoutinordertojustifythe
businesscaseofthemodularhoodproposal.
Inordersucceedinamodulararchitecture,thewholeportfolioneedstobedeveloped
inparalleluntiltheendoftheconceptphasetosecurefullbenefitofit.Finaldesigncan
bedonelaterandintroducedinsequencemaintainingtheinterfacesdefined.
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7. CONCLUSIONS AND RECOMMENDATIONS This chapter describes the important findings of the study and also the
recommendationsforthefuture.
7.1 IMPORTANT FINDINGS Thisprojectfollowedthefootstepsofthemodularcabdesign.Theoveralloutputofthe
studyresultedintheproposalofacommonproductarchitecturecoveringfourdifferent
product categories for thedesignof thehood.Amodulararchitecture for thegrille is
also proposed. Possible assemblymethods for the interfaces of the individual panels
andgrillemeshesinthehoodhavealsobeenproposedwhichneedsadditionalresearch
oneconomicviability.
Themethodofoptimizationused toachieve the leastnumberofpartnumbers in the
designofthegrillemesheswasveryeffectiveinreducingthenumberofpartnumbers
from32to26.Thenumberofpartnumberscanbereducedfurtherto20bybreaking
downthemeshesintosmallerpartsbuttheeffectonmanufacturingneedstobestudied
before a decision is made. The entire design proposal is based on the fact that few
changes are made to the existing systems. From the study, the benefits of having
modularproductarchitecturefaroutweightheexistingintegraldesignsolution.
The 3DX platform plays an important role in documenting the technical solutions
effectively.The seamless integrationbetween thewebandCAD interface reduces the
time taken to document the solutions. The requirementmanagement app allows the
usertoeffectively tracetherequirements fromthemoment it iscapturedtohowit is
captured into the design. The documentation of the solution can be done inmultiple
waysbutinthisprojectthedocumentationisdoneinamannertosuittheinterestsof
designersandproductmanagers.
7.2 RECOMMENDATIONS Furtherresearchneedstobecarriedoutonmathematicalmethodsthatcanbeusedto
reducethenumberofparts further.Theproposedmanufacturingmethodsneedtobe
evaluatedwithrespecttoperformanceandeconomicstofurthervalidatetheproposal.
Further steps needs to be taken to implement a product architecture for the engine
compartment. If theproductarchitectureoftheenginebay isestablishedfordifferent
productcategories,aclearunderstandingofthevariableswhichaffectthedesignofthe
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hoodcanbeobtained.Futuredesigns canmakeuseof theenginebayarchitecture to
definethevariableswhichdrivethedesignofthehood.
With respect to the 3DX platform, other features of the software with respect to
manufacturingcanbeusedtodemonstratethemanufacturingprocessoftheproposed
modularhood.Theimpactofdifferentrolescanalsobeemphasizedinthesame.
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REFERENCES
Baldwin, C.Y. & Clark, K.B., 1997. Managing in an age of modularity. Harvard business review, 75(5), pp.84–93.
Banker, R.D., Bardhan, I. & Asdemir, O., 2006. Understanding the impact of collaboration software on product design and development. Information Systems Research, 17(4), pp.352–373.
Boothroyd, G. & Alting, L., 1992. Design for Assembly and Disassembly. CIRP Annals - Manufacturing Technology, 41(2), pp.625–636.
CAT, 2015. Caterpillar. Available at: http://www.cat.com/en_US/products/new/by-industry/construction.html [Accessed January 3, 2015].
Dahmus, J.B., Gonzalez-Zugasti, J.P. & Otto, K.N., 2001. Modular product architecture. Design Studies, 22(5), pp.409–424.
Dynapac, 2015. Dynapac. Available at: http://www.dynapac.com/en/Products/ [Accessed January 4, 2015].
Gokpinar, B., Hopp, W.J. & Iravani, S.M.R., 2013. In-house globalization: The role of globally distributed design and product architecture on product development performance. Production and Operations Management, 22(6), pp.1509–1523.
Hinze, J.W. & Teizer, J., 2011. Visibility-related fatalities related to construction equipment. Safety Science, 49(5), pp.709–718. Available at: http://linkinghub.elsevier.com/retrieve/pii/S0925753511000099 [Accessed December 28, 2014].
Komatsu, 2015. Komatsu. Available at: http://www.komatsuamerica.com/ [Accessed January 4, 2015].
Ülkü, S. & Schmidt, G.M., 2011. Matching product architecture and supply chain configuration. Production and Operations Management, 20(1), pp.16–31.
Ulrich, K., 1995. The role of product architecture in the manufacturing firm. Research Policy, 24(3), pp.419–440.
Ulrich, K. & Eppinger, S.D., 2012. Product Design and Development . McGraw-Hill Higher Education, (5).
Wits, W.W. & Vaneker, T.H.J., 2011. TRIZ based interface conflict resolving strategies for modular product architectures. In Procedia Engineering. pp. 30–39.
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APPE
INTERVINTERV
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68
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INTE
SOIL
TERVIEW QU
L COMPACT
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AIRE – ANSW
69
WERS
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WHEEL
LOADER ANND ARTICULLATED HAU
70
ULERS
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APPE
GENERA
ENDIX
AL REQUIRE
II
EMENT STRRUCTURE
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INTERFA
FACE DEFINIITION
73
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APPE
REQUIR
ENDIX
REMENT MA
III
ANAGEMENNT SUMMA
75
ARY – COMPPLETE – MOODULAR HO
OOD
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RELATIO
CONFIG
ONSHIP BET
GURATION F
TWEEN REQ
FEATURES A
QUIREMENT
AND OPTIO
77
TS AND CON
ONS – COMP
NFIGURATI
PLETE – MO
ION OPTION
ODULAR HO
NS
OOD
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CONFIGGURATION RRULES SUMMMARY
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MARKE
ETING PREFE
FERENCES SUUMMARY
79