project work, spring 2002 chalmers chalmers machine and vehicle systems production engineering...
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Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Machine Elements and Manufacturing Engineering joint project, Y2, spring 2002
Introducing a Design-build experience
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Overall project aims
• Practice collaboration and project management (Concurrent engineering)
• Apply theory from courses in Machine Elements and Manufacturing Engineering
• Gain insight and understanding on how to use design and analysis methods throughout the product realization process
• Practice oral and written communication skills
• Utilize projects from industry
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Assignment Measurable criteria
Concept development
Who? Why? When?
What ? (Max, min, number, weight etc.)
How?
The purpose
State requirements specFunctional analysis
Problem definition
Project planning Analyse and test of prototype
Prototype buidlConcept evaluationConcept refinementIdea generation
Further development of concept
Kravuppfyllnad
Functional verification
The process
The Design Process
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
ActivityMethod/ToolPurpose/aimTutoring1Problem definitionHandoutsDefine project purpose and aims2Project planningGantt chartIdentify project steps, time and resource planning3Requirement specificationFreddy Olssons matrixChecklist - Pugh’s Design CoreInformation searchMeasurable criteria4Functional analysisBlackboxIdentify main function and subfunctions15Idea generationBrainstormingFind/create solutions for subfunctions6Idea selectionHandoutsReject solutions that cannot be realized or thatare not safe7Idea systematizationClassification schemeCreate additional solutions8Combination of partialsolutionsMorfological matrixDocument sub-solutions and combine these intosystem solution9Further development ofselected conceptsHandoutsDevelop the concepts to a similar degree ofdetail210Evaluation 1Pugh’s relative decision matrixIdentify strengths and weaknesses wrt the criteria11Concept refinementHandoutsImprove concepts wrt minus (-) scores12Evaluation 2Pugh’s relative decision matrix(choose new reference)Select 3-4 concepts for futher development13Prototype manufacturingSelect one concept for prototypemanufacturingProE CAD modellingManufacture one prototype variant414Analysis of prototypeHandoutsAnalyse function and requirements fulfillment15Sel of manufacturingprocess, cost estimationSWIFTRedesign concepts for manufacturing616Evaluation 3Concept scoring + KesselringSelection of final concept17Further development ofthe selected conceptHandoutsDetaila dimensions, tolerances,materials selection etc.718Documentation andpresentationHandouts, course memoDokumentation of working process andfinal design8
Scope
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Prototype build - purpose
• Physical/geometric verification of the concept solution
• Verify requirements fulfillment
• Functional analysis
• DFM – DFA
• Form – Aestethics - Feel
• Identify weaknesses/improvements
State requirements specificationFunctional analysis
Analysis and test of the prototype
Concept evalutionConcept refinement
Requirements fulfillment & functional verification
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Prototype
Select concept for prototype manufacturing
CAD modeling (ProE)
Manufacturing
Analysis
Koncept123456789KriterieA+0+R+-+-+B0-0E--0+-C++0F0+0+-D---E0-0--E++-R+-+-+F+0+E+0000
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+422N31222
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-122S14033
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0122621411 . Tot
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30002-32-1-1Placering133325244
SLA, SLS (CARAN)
Function and requirements fulfillment
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Project assignment
• All projects were from industry– Added realism and motivation
• Passenger car handle (Volvo Car Corp)• Fan valve for airfreight container (Envirotainer)• Adjustable bracket for radio link antenna (Viking
Microwave)
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Adjustable bracket for radio link antenna
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Results from prototype
manufacturing
• Total 71 pcs
• SLA & SLS
”Full” prototypes were built by adding standard parts
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Reflections
• Positive reactions from the students– ”it’s was fun with physical feedback”– ”realistic and meaningful - motivating”– ”oops … it didn’t work ….”– ”the physical prototype made it easier to find weaknesses
and come up with improvements”– ”deeper understanding of the function”,
• Teacher:– more motivated students– industry relevance, deadlines, milestones, deliverables– more work– reasonable cost (5 700 USD for 71 “prototypes”)
Project work, spring 2002
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
CHALMERS CHALMERS
Machine and Vehicle Systems Production Engineering
Future
• Plan to run the project with similar scope next year
• Improved student design-build facilities through the prototyping lab
• Continued collaboration with CARAN
• Carefully selected project assignments