Unsettled Technology Areas in Deterministic Assembly Approaches for Industry 4.0

Increased production rates and cost reduction are affecting manufacturing in all sectors of the mobility industry. One enabling methodology that could achieve these goals in the burgeoning “Industry 4.0” environment is the deterministic assembly (DA) approach. The DA approach is defined as an optimized assembly process; it always forms the same final structure and has a strong link to design-for-assembly and design-for-automation methodologies. It also looks at the whole supply chain, enabling drastic savings at the original equipment manufacturer (OEM) level by reducing recurring costs and lead time. Within Industry 4.0, DA will be required mainly for the aerospace and the space industry, but serves as an interesting approach for other industries assembling large and/or complex components. In its entirety, the DA approach connects an entire supply chain—from part manufacturing at an elementary level to an OEM’s final assembly line level. Addressing the whole process of aircraft design and manufacturing is necessary to develop further collaboration models between OEMs and the supply chain, including addressing the most pressing technology challenges. Since all parts aggregate at the OEM level, the OEM—as an integrator of all these single parts—needs special end-to-end methodologies to drastically decrease cost and lead time. This holistic approach can be considered in part design as well (in the design-for-automation and design-for-assembly philosophy). This allows for quicker assembly at the OEM level, such as “part-to-part” or “hole-to-hole” approaches, versus traditional, classical assembly methods like manual measurement or measurement-assisted assembly. In addition, it can increase flexibility regarding rate changes in production (such as those due to pandemic- or climate-related environmental challenges). The standardization and harmonization of these areas would help all industries and designers to have a deterministic approach with an end-to-end concept. Simulations can easily compare possible production and assembly steps with different impacts on local and global tolerances. Global measurement feedback needs high-accuracy turnkey solutions, which are very costly and inflexible. The goal of standardization would be to use Industry 4.0 feedback and features, as well as to define several building blocks of the DA approach as a one-way assembly (also known as one-up assembly, or “OUA”), false one-way assembly, “Jig-as-Master,” etc., up to the hole-to-hole assembly approach. The evolution of these assembly principles and the link to simulation approaches are undefined and unsolved domains; they are discussed in this report. They must be discussed in greater depth with aims of (first) clarifying the scope of the industry-wide alignment needs and (second) prioritizing the issues requiring standardization. NOTE: SAE EDGE™ Research Reports are intended to identify and illuminate key issues in emerging, but still unsettled, technologies of interest to the mobility industry. The goal of SAE EDGE™ Research Reports is to stimulate discussion and work in the hope of promoting and speeding resolution of identified issues. SAE EDGE™ Research Reports are not intended to resolve the challenges they identify or close any topic to further scrutiny.

Analysis of Design For Assembly (Dfa) in Exhaust Product Design

GRIP Exhaust is a small and medium industry which is engaged in manufacturing which produces mufflers. The production system in this company is to apply a production system made to order, where consumers can order exhaust products according to their requests. Designing exhausts according to technical specifications by applying the Design For Assembly (DFA) method and calculating the time required to assemble custom exhaust products into technical specifications by producing products according to user needs. With Design For Assembly (DFA) to make it easier and push time, but still focus on the function of the product itself and pay attention to the safety factor of its performance. custom stainless steel exhaust takes 2 hours to complete, rust-resistant quality, an efficiency value of 1.23, and has higher advantages and attractiveness in the eyes of consumers.

CONCEPTUAL DESIGN FOR ASSEMBLY IN AEROSPACE INDUSTRY: SENSITIVITY ANALYSIS OF MATHEMATICAL FRAMEWORK AND DESIGN PARAMETERS

One of the most challenging activity in the engineering design process is the definition of a framework (model and parameters) for the characterization of specific processes such as installation and assembly. Aircraft system architectures are complex structures used to understand relation among elements (modules) inside an aircraft and its evaluation is one of the first activity since the conceptual design. The assessment of aircraft architectures, from the assembly perspective, requires parameter identification as well as the definition of the overall analysis framework (i.e., mathematical models, equations).The paper aims at the analysis of a mathematical framework (structure, equations and parameters) developed to assess the fit for assembly performances of aircraft system architectures by the mean of sensitivity analysis (One-Factor-At-Time method). The sensitivity analysis was performed on a complex engineering framework, i.e. the Conceptual Design for Assembly (CDfA) methodology, which is characterized by level, domains and attributes (parameters). A commercial aircraft cabin system was used as a case study to understand the use of different mathematical operators as well as the way to cluster attributes.

REDESIGN PENYEMPROT DESINFEKTAN DENGAN METODE DESIGN FOR ASSEMBLY

Pada dasarnya proses desain merupakan langkah awal dari proses manufaktur. Sebagaian besar biaya produksi ditentukan dalam proses desain dan perancangan. Jumlah komponen dan sistem perakitan yang diguanakan sangat berpengaruh terhadap biaya perakitan dan lama waktu perakitan. Setiap produk memiliki komponen – komponen penyusunnya. Antara lain dari bagian pertama merupakan dasar bentuk, ukuran dan tujuannya. Pada bagian kedua terdapat spesifikasi dari produk itu antara lain harga, bahan kemasan, kualitas, nama, jenis. Pada tahap pengembangan alat penyemprot desinfektan peneliti menggunakan analisis dengan metode DFA (Design For Assembly). Kesimpulan dari penelitian didapatkan hasil pengembangan produk alat penyemprot desinfektan secara otomatis dengan pencitraan termal ntanpa sentuhan diperoleh harga sebesar Rp. 1.123.000,00 sedangkan untuk produk awal sebelumnya dikembangkan memiliki harga relatif murah dari produk sebelumnya dengan selisih harga Rp. 627.000,00 dan Selain itu produk pengembangan juga mempunyai keunggulan dalam penggunaannya, jika alat penyemprot desinfektan yang awal hanya menyemprotkan cairan desinfektan saja maka produk inovasi ini di lengkapi dengan sensor gerak, jadi ketika ada yang melewati alat tersebut maka secara otomatis alat ini akan menyemprotkan cairan desinfektan. Tidak hanya itu, alat ini juga dilengkapi dengan sensor suhu yang akan membaca suhu tubuh setiap manusia yang memasuki alat tersebut, dan ketika ada salah satu manusia yang suhunya diatas 37 derajad maka alat ini secara otomatis akan mengirimkan notivikasi pada handphone pihak keamanan setempat untuk ditindak lanjuti.

Rancang Bangun Mesin CNC (Computer Numerical Control) Laser dengan Metode Design for Assembly

CNC Laser (Computer Numerical Control) adalah alat yang memiliki fungsi untuk mengukir/mencetak berbagai tulisan dan kaliqrafi secara otomatis berdasarkan media yang digunakan seperti Acrilic, Fiber, Almunium, dan kayu. Perancangan CNC laser menggunakan metode Design For Assembly Boothroyd (DFA), G-Code, dan Closed Loop System (Loop Tertutup). Kelebihan metode DFA yaitu mengestimasikan pengurangan waktu perakitan. Metode G-Code lebih ke menyatukan gerakan yang akan di lakukan mesin, seperti bergeser ke titik A, titik B. Kemudian pada metode Closed Loop System (Loop Tertutup) bekerja mengirim sinyal umpan balik ke pengendali untuk mengecilkan kesalahan sistem. Hasil pengujian dari komponen pada masing-masing alat secara keseluruhan berupa input dan output menjadi kesatuan alat mesin CNC laser cutting dan engraver. Software GRBL dihubungkan pada CNC shild. GRBL mengirim G-Code ke arduino dan menerjemahkan isi dari G-Code satu persatu untuk menghasilkan pergerakan motor stepper dan cahaya laser. Telah didapatkan sistem pengontrolan mesin laser engravir yang bisa menggerakkan mesin kearah dua sumbu X dan Y, yang tersusun dari beberapa komponen yaitu komputer, kontroler arduino nano, motor stepper, laser module, power supplay dan emergency stop. Pengujian laser engraver dilakukan dengan medium plywood dan berbagai pola gambar. Hasil pengujian menunjukkan alat dapat bekerja sesuai dengan pola gambar yang ada.CNC Laser (Computer Numerical Control) tools that have a function to automatically engrave / print various writings and kaliqrafi based on the media used such as Acrilic, Fiber, Aluminum, and wood. CNC laser design uses the Design For Assembly Boothroyd (DFA), G-Code, and Closed Loop System (Closed Loop) method. The advantage of the DFA method is that it estimates the reduced assembly time. The G-Code method is more about unifying the movements that the machine will do, such as moving from point A to point B. Then the Closed Loop System method works to send a feedback signal to the controller to minimize system errors. The test results of the components on each tool as a whole are in the form of input and output into a unity of the CNC laser cutting and engraver machine tool. GRBL software is linked to the CNC shild. The GRBL sends the G-Code to the Arduino and translates the contents of the G-Code one by one to produce stepper motor movement and laser light. A schematic of a laser engraving machine control system that is able to move the machine towards two axes X and Y, which is composed of several components, namely a computer, Arduino nano controller, stepper motor, laser module, power supply and emergency stop. Laser engraver testing was carried out using plywood and various image patterns. The test results show that the tool can work in accordance with existing image patterns.