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TRANSCRIPT
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Contents
1. The analyses of fitting performance of the initial product..................................................................... 2
1.1 Project requests............................................................................................................................. 2
1.2 The initial product sketch.............................................................................................................. 2
1.3 The initial product structure .......................................................................................................... 4
1.4 The application of DFAFD for the initial product .......................................................................... 5
1.5 The list of weak points of the initial product and the priority of interventions ................................ 6
2. Development the final version of the product........................................................................................ 6
2.1 The improved version of the product ............................................................................................. 6
2.2 The final product structure ............................................................................................................ 7
2.3 The application of DFAFD for the initial product .......................................................................... 8
3. The robotic cell concept ....................................................................................................................... 9
3.1 General presentation ..................................................................................................................... 9
3.2 Robotic cell detailed description ................................................................................................. 10
4. The economic evaluation of the robotic cell ........................................................................................ 11
4.1 Summarizing table of the necessary equipment ........................................................................... 11
4.2 Economic justification of the robotic assembly system solution................................................... 11
5. Ladder diagram for controlling the process ......................................................................................... 13
5.1 List table for inputs outputs ......................................................................................................... 13
6. Conclusions........................................................................................................................................ 16
7. Bibliography ...................................................................................................................................... 17
8. Annexes ............................................................................................................................................. 17
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1. The analyses of fitting performance of the initial product
1.1 Project requests
For this project we have to improve a signal lamp used in mines and in other harsh
environments. We also have to build a robotic cell where we can assembly the lamp faster and more
productive in economic terms, because now our product is made in a normal factory without robots.
There is also an economical challenge to try to produce a product faster and cheaper than the
initial one, for that we have to do economical study and production study.
Assembly represents an important step in the whole production process because this
operational activity is responsible for an important part of the total production costs and the
throughput time. It is one of the most labor-intensive sectors in which the share of the costs could
be 2575% of the total production cost. Practice has proved that the share of the labor cost in the
assembly, in relation to the total production costs, are around 45% for car engines, 55% for
machine-tools, 65% for electrical apparatus. This is because the automation within the
manufacturing process is larger by far than in the case of assembly process.
For the analysis and redesign of the product and the related assembly process will be
presented a concept called DFAFD (design for assembly function deployment) proposed by
Rompesad in 1993. Mainly, this method aims to force the designer to think comprehensively about
the product and process design before proceeding to the development of the assembly system.
1.2 The initial product sketch
The initial product (fig 1.1) is made of:
a) Top lid;b) Bottom lid;c) 3 screws;d) Gasket;e) Electrical module;
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Fig 1.1 The initial product
The dimensions of the lamp are presented in the table 1.1
A B C D E
64 mm 49.8 mm 5 mm 30.5 mm 68 mm
Table 1.1
Where: A top lid diameter;
B top lid height;
C top lid flange height;
D bottom lid height;
E bottom lid diameter;
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1.3 The initial product structure
The interdependencies diagram of component parts for the initial product is presented in
fig 1.2
Fig 1.2
The inter-relations structure of component parts for the initial product is presented in fig 1.3
Fig 1.3
Lamp
Electronic ModuleLid
Screws Lid
Body
Base Gasket
Electronic Module
Body
BaseGasket
Lid Screws
Lid
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The sketch of assembly process for initial product is presented in fig 1.4
Fig 1.4
1.4 The application of DFAFD for the initial product
For the analysis of the initial product and the assembly process will be use the DFAFD
method. The result of the DFAFD is presented in table 1.21.
Table 1.2 [ Snapshot from Excel 2010]
1For complete DFAFD table check Annex 1
Base Electronic
module
LidScrews
Gasket
Gripper a Gripper 3Gripper 1Gripper 1 Gripper 2
Acceptable
Defective
gripper
exchange
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1.5 The list of weak points of the initial product and the priority of interventions
The weak points and the priority of interventions are presented in the table 1.3
Weakness points Interventions
Gasket It will be directly cast in the bottom lid
Screws It will be removed
Top lid It will be redesign
Table 1.3
The gasket is a weak point because is hard for a robot to mount it on the bottom lid so for
that it must be somehow eliminated or replaced with something else. We have to keep in mind that
the lamp will be used in mine where water infiltration and other impurities are often met. From the
DFAFD table we can see at Stiffness section the difficulty for flexible is 4 which is not good for our
percentage.
The screws are also very hard to mount for a robot so we have to eliminate them and for that
the top lid must be redesign. Also we can see that in the DFAFD table at section Joining method the
difficulty forScrewing or adhesive bonding is 4 which will lead to a higher percentage of difficulty
and because a screw can only be screwed we must eliminate them.
2. Development the final version of the product
2.1 The improved version of the product
At the previously chapter we highlights the weakness points and now we try to solve the
problems. The gasket will be cast in the bottom lid so that the robot wont have to mount it. The
screws will be removed because the mounting is made directly between the top lid and the bottom
one with the aid of 2 clamps (fig 2.1).
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Fig 2.1 [Snapshot from Catia V5R19]
2.2 The final product structure
The interdependencies diagram of component parts for the final product is presented in
fig 2.2
Fig 2.2
The inter-relations structure of component parts for the final product is presented in fig 2.3
Fig 2.3
Lid Electronic Module
Body
Clam s
Top lid
Lamp
Electronic ModuleLid Body
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The sketch of assembly process for final product is presented in fig 2.4
Fig 2.4
2.3 The application of DFAFD for the initial product
After we rethink and redesign the product we made the DFAFD simulation to find out if our
product is better than the previous one. The result is presented in the table 2.12
Table 2.1 [Snapshot from Excel 2010]
2For a complete DFAFD Table Check Annex 2
Electronic
module
Top Lid Body
Gripper 1 Gripper 1 Gripper 1
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If we compare the Table 1.2 with Table 2.1 we can see an improvement between the 2 lamps
from 57.52% to 63.25% is not a big difference at first sight but after all economic calculations the
second product is cheaper and more easier to produce which leads to a bigger profit.
3. The robotic cell concept
3.1 General presentation
The robotic cell (fig 3.1) that we create for assembly the lamp is made from:
a) 1SCARA robot Adept 2.1b) 4 conveyors Dorner 22003c) 1 index table from FIBROTOR4d) 1 vacuum gripper from SCHUNK5
Fig 3.1 [Snapshot from Catia V5R19]
3The Dorner Catalogue is presented in Annex 3
4The Fibrotor Catalogue is presented in Annex 4
5The Schunk Catalogue is presented in Annex 5
d
a
b
c
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3.2 Robotic cell detailed description
The 3 conveyors are feed by a worker. This will place the parts for each conveyor until they
are fully occupied. The parts will be carefully placed between the two red lines.
After the conveyors are completed with parts the assembly process is started. The parts will
go towards the index table which has a color-detection sensor which will detect the red line in front
of them. When the red line comes into the range of the sensor this will send a signal to stop the
conveyors. The index table contains 3 slots supporting the parts and in the initial state the slots are
directed towards the conveyors.
The actual assembly will take place as follows: the table rotated until the electric module is
under the gripper. The robot pick the electric module and keep it suspended until the bottom lid is
under the gripper than place the electric module on the lid. The final step in the assembly process is
putting the top lid over the two parts that are already assembled.
After all the parts are put together the robot takes the final product and move it on the final
conveyor which transport the lamp to palletizing station.
When the assembly process is finished the index table returns to the initial state and send a
signal that will starts the conveyors. We also have a sensor that counts how many parts are on the
conveyor and when there remain only two a signal will trigger which will announce the worker that
the conveyors must be feed.
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4. The economic evaluation of the robotic cell
4.1 Summarizing table of the necessary equipment
Indicative values for the economic evaluation of robotic assembly cell are presented in
table 4.1.
Crt.
NRComponents Price ()
6
1 Parts Storages 800
2 Conveyor and Command 8.000
3 Index Table 1.500
4 Limitated contactor course 10
5 Proximity sesnor 50
6 PLC 2.000
7 Vacuum gripper 700
8 Inspection system 12.000
9 SCARA Robot 15.000
Table 4.1
4.2 Economic justification of the robotic assembly system solution
Economic profitability of a certain conception-design alternative for a robotic assembly
system it is identified by means of a coefficient called integral productivity IP7.
If IP
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We can see that for a period of10 years at a price of18 RON/ lamp the integral productivity
will be 1.9. Also we want to know if we can absorb the investment in sooner then 10 years. The
results are presented in table 4.2
Number of years Integral productivity (Ip) Lamp price (RON)
10 1.9 18
5 1.6 18
3 1.4 18
1.5 1.0 18
Table 4.2
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Conclusion: if we manage to maintain the product price at 18 RON/ Lamp not only that we
will absorb the investment in 1 year and a half, but we also start to make some profit.
5. Ladder diagram for controlling the process
5.1 List table for inputs outputs
Inputs Addresses Outputs Addresses
1st sensor of the 1
st conveyor X00 1st conveyor Y00
2nd
sensor of the 2nd
conveyor X01 2nd
conveyor Y01
3rd
sensor of the 3rd
conveyor X03 3rd
conveyor Y02
1st
position of the index table X04 4th
conveyor Y03
2
nd
position of the index table X05
1st
subroutine (takes the
electric module) Y04
3rd
position of the index table X062
ndsubroutine (place the
electric module)Y05
4th
position of the index table X073
rdsubroutine (takes the top
lid)Y06
Second to last position on the
conveyorX08
4th
subroutine (place the top
lid)Y07
Proximity sensor for 4th
conveyorX09
5th
subroutine (move the final
product)Y17
1st
subroutine of the robot X10 Activate the alarm Y08
2nd
subroutine of the robot X11Move the index table
clockwiseY09
3rd subroutine of the sensor X12Move the index table
counterclockwiseY10
4th
subroutine of the sensor X13 Starting internal contact Y11
5th subroutine of the sensorX14
Product counter Y12
Start button X15 Stop the process Y13
Stop button X16
Alarm stop button X17
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Fig 5.1 Ladder diagram
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6. Conclusions
The purpose of this project was to try to improve a given product. For achieving our goal we
applied the methods learned along entire semester. After we analyses the product and applied
the DFAFD method we design a new and improved product.
What we can conclude is that: if we respect strictly all the steps and analyze correctly the
DFAFD result we can improved the product both technical and economic. Which will lead to a
higher productivity and higher income for our client.
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7. Bibliography
Course support :Robotization of the Assembly Processes Prof.Dr.Ing.Stelian BRAD
8. Annexes
Annex 1: Firs DFAFD
Annex 2: Second DFAFD
Annex 3: The Dorner Catalogue
Annex 4: The Fibrotor Catalogue
Annex 5: The Schunk Catalogue