Design for disassembly and augmented reality applied to a tailstock

The work here described aims to offer a starting point for improving and making a generic maintenance process more efficient, first of all thanks to the use of a cutting-edge technology such as augmented reality, as a key tool that makes it possible and immediate to communicate to operators which are the fundamental stages of the maintenance process to be followed in the working area. Furthermore, thanks to the use of two methods applied in the context of the Design for Disassembly (later described), we also propose to search for all the possible sequences to get to the removal of a target component to be adjusted—in particular the optimal one (if it exists, in terms of time and costs) to be subsequently applied in an augmented reality “self-disassembly” model that can be viewed and followed by the operator, in a way that is still very little used today

Maintainability of a gearbox using design for disassembly and augmented reality

Environmental impact and recycling have been increasingly frequent topics in recent years. At the same time, the life cycle of products has increasingly become shorter, as the escalating competitive market requires new products in smaller pieces. From this perspective, the recovery of parts and products that are produced in this market system for subsequent reuse when they reach the end of their life cycle is essential. For these reasons, it has become critical that companies re-evaluate their product design with a view to the possible recovery of the parts that comprise their products and to create new products for the market. The following discussion was based on the study of design for disassembly (DfD), which is the analysis of industrial products aimed at optimizing disassembly in terms of time and costs. The application of the DfD to a case study of a gearbox has, among its main objectives, the search for the best disassembly sequence in terms of time and money. During the course of the study, augmented reality (AR) was used. Through the use of the Unity software and Vuforia package, it was possible to bring the gearbox back to AR and then simulate the disassembly sequence in AR

Design for six sigma (DFSS) applied to a new eco-motorbike

The primary purpose of this work is to organize, in the best possible way, the design of an ecological transport vehicle, using an advanced design methodology, namely design for six sigma (DFSS). The DFSS is indeed a design approach, able to implement, in a logical and integrated way, other advanced methodologies of systematic design, such as quality function deployment (QFD), TRIZ (in Russian, Teorija Resenija Izobretatel'skich Zadac), benchmarking, top-flop analysis and others, in order to propose design solutions oriented both to quality and innovation, for satisfying customers. The above described has been demonstrated through the application of DFSS to a case study in which the set up phase of an industrial project was completed, without having overlooked any aspect useful for obtaining a new attractive product. The case study concerns the application of DFSS to a new low-polluting motorcycle. At the end of the work, the designer obtained the achievement of the conceptual project

Method for evaluating the durability of aircraft piston engines

A significant issue in aircraft engines is quantifying residual life to overhaul. The algorithm described in this paper calculates with a good level of reliability the residual life of a petrol piston engine. The method was tested on small, latest-generation, naturally-aspirated aircraft and racing piston engines, and has been effective in several experiments. This method is implemented directly on the electronic control system of the engine with very few lines of C-code. The method can also be used in many industrial engines. This innovative method assumes that only two main factors (power level and wear) affect engine durability or time between overhauls. These two factors are considered as separate and combined with worst case criteria. The wear is assumed to follow a logarithmic law and a formula similar to the Miner’s law for material fatigue is used, making it possible to calculate the power-level curve with knowledge of only two points. The wear-curve is also related to elapsed engine cycles. The algorithm is very simple and can be implemented with just a few lines of software code accessing data collected from existing sensors. The system is currently used to evaluate actual residual life of racing engines

Revised KAD Tool To Optimize F1 Cars Through A Combined-Elitarian Genetic-Fuzzy Algorithm

The KAD(Knowledge Aided Design) tool is developed to predict the performance of an F1 car in different driving conditions and with different configurations. The regulations to put in trimming a car, also in the exasperated technology of the competitions, still demand a remarkable dose of luck and an elevated number of tests. It is then important to know a set of regulations close to the optimal trim before testing the car on the track. The difficult phase of this process is to evaluate the lap time. As a matter of fact driving style, track conditions and car behavior should be simulated. The optimisation of the fuzzy controller that simulates the pilot for an F1 racing car is difficult due to handling problems and velocity of response. For this purpose a specific Genetic Algorithm (GA) was conceived and tuned to work with a lumped mass model of an F1 racing car for the optimization of the fuzzy controller that simulates the pilot. A new mutation and a new crossover operator were defined to complement the standard crossover and mutation operators of the basic Holland\u2019s GA. This was necessary in order to increase the overall performance of the fuzzy pilot. This approach was tested on an F1 car due to the huge amount of data available (Donnarumma, 1998; Moelenbein, 1989; Lee and Takagi, 1993)

Virtual mechanical product disassembly sequences based on disassembly order graphs and time measurement units

Recently, the approach that defines the total life cycle assessment (LCA) and the end of life (EoL) in the early design phases is becoming even more promising. Literature evidences many advantages in terms of the saving of costs and time and in the fluent organization of the whole design process. Design for disassembly (DfD) offers the possibility of reducing the time and cost of disassembling a product and accounts for the reusing of parts and of the dismantling of parts, joints, and materials. The sequence of disassembly is the ordered way to extract parts from an assembly and is a focal item in DfD because it can deeply influence times and operations. In this paper, some disassembly sequences are evaluated, and among them, two methods for defining an optimal sequence are provided and tested on a case study of a mechanical assembly. A further sequence of disassembly is provided by the authors based on experience and personal knowledge. All three are analyzed by the disassembly order graph (DOG) approach and compared. The operations evaluated have been converted in time using time measurement units (TMUs). As result, the best sequence has been highlighted in order to define a structured and efficient disassembly

Industrial Design Structure: a straightforward organizational integration of DFSS and QFD in a new industry and market reality

Purpose: The aim of this research is to enlighten the methodology model of Industrial Design Structure (IDeS) that integrates the internal and external customer feedback embodied both in methods of quality function deployment (QFD) and as basis of design for six sigma (DFSS) steps to systematically bring the information across the entire organization, saving overall product development time and resources. Design/methodology/approach: The paper describes the state of the art enlightened to establish the disadvantages and challenges of other methods taken into consideration in the study like QFD and DFSS that, together with the need of companies to react fast to changes they need to straightforwardly implement product development information across all departments, leading to a mass customization infrastructure. Several application trials of this methodology have been cited. Findings: The IDeS method has established to been able to integrate other well-known methodologies to gather technical specifications starting from voice of customers (VOCs) like QFD that served to canalize the generalist approach of define, measure, analyze, design and verify (DMADV) of DFSS in order to reach into a larger share of the organization and englobe by following the overall product design steps of an industrial project. Research limitations/implications: The research approach chosen for this document presents the concept of a methodology ought to operate most internal branches in a company driven by product design requirements and guidelines. Therefore, researchers are encouraged to develop further studies on the IDeS method are required in order to adapt this methodology to specific management tools that would help to ease information gathering for immediate analysis and modification. Practical implications: The paper implicates that a need to interchange information systematically across all subdivisions in the organization, as brisk response to VOC reactions is needed to thrive in the market nowadays, leading to a fast product customization scene. However, the industry is heading into adopting an individual customer-centered product conceptualization ought to be driven by design as a key for individualizing an object. Afterward by taking this concept broadly and adopting it would lead to implement a company organization that would be directly affected by the customer's input. Social implications: The methodology described aims to enable organizations to portray fast and accurate product prototyping, by exploiting technologies from Industry 4.0. Originality/value: This concept proposes a method to canalize the implementation of DFSS by using the DMADV approach, whilst assessing the challenges of adaptation and keeping up with cultural pace that impacts the behavior of buying and consumption and moreover implementing a seamless communication within all departments in the organization to share the development progress and change requests by using similar information technology tools. This would imply important savings in resources, whilst delivering quality products to the society

On the Avant-Garde IDeS Method for the Future of Car Design Applied to an SUV Project

This case study aims to develop a new innovative SUV (Sport Utility Vehicle) model exploiting IDeS (Industrial Design Structure), which is an engineering approach conceived to optimize car design projects in the automotive industry like never before. A compact SUV was chosen because it is a type of vehicle that is highly requested by customers, and it is extremely successful in the market due to its versatility. In fact, compact SUVs are mixed vehicles that combine the pragmatism of a car with the typical robustness of an off-road vehicle making them suitable both for urban and off-road scenarios. The following pages will illustrate the steps followed for the realization of the final product using the SDE (Stylistic Design Engineering) method and other various design technologies, such as Quality Function Deployment (QFD), Benchmarking (BM) and Top Flop Analysis (TPA). In the final part of this project, the virtual prototyping of the product is carried out using Additive Manufacturing (AM) with an FDM 3D printer. The combination of these methods forms, to all intents and purposes, the IDeS, a newly developed innovative and cutting-edge discipline capable of schematically guiding the new product development process in companies with unprecedented efficiency

Design for Six Sigma and TRIZ for Inventive Design Applied to Recycle Cigarette Butts

A deep research and analysis of a “critical waste” object has been carried out, understood as a subject that does not fare high on the separate collection and recycling system yet: the cigarette butt. This acknowledged social waste is the first among all the garbage detected everywhere around neighborhoods worldwide, and is therefore the epicenter of a situation so worrying that it is necessary to find a solution concerning the environmental pollution. The present exercise was developed, by means of proper product design methods like TRIZ and QFD driven by DFSS rulings, to conceive of new products and services in order to create incentive for the smokers to lessen the environmental pollution problem. The social implications are about the possibility of modifying the bad habits of the smokers and making the user act consciously towards the environment. Throwing the cigarette-stub in the new collection device, rather than on the ground, enables users to enjoy both moral and economic returns. The “Buttalo” service is aimed to incentivize the population to fight against environmental pollution whilst helping smokers to be conscious about it

Electric Bike Product Conception and Styling According to Design Trends

The following case study portrays the several steps required to conceive a product from scratch. The first step involves an in-depth analysis of today’s electric bicycle market in order to obtain data and information relating to the levels of innovation and comfort required by customers. Then, we evaluate the implementation of a useful method to understand the level of innovation that the product must have to be competitive on the market. The second part studies the architecture of the product, considering the different components already sold on the market which will become part of the project. The third part concerns a comparison between different stylistic trends that the vehicle may have (in order to outline the best one). The fourth part concerns the CAD realization of the virtual model complete with all its parts, including a structural verification study of the frame. The last part studies the presentation of the product to the customer, exploring different effective ways to communicate what the strengths of the new product will be (also allowing them to customize it before its realization). The plan for the realization of the new product, starting from the concept to arrive at the final presentation to the customer, follows the methods proposed by applying a series of steps to develop a generic new product in an efficient, sensible, and methodical manner. Therefore, we will refer to quality function deployment (QFD), benchmarking (BM), design for X, until reaching the final prototyping and testing phases