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

EFFECT OF TRAINING AND SUDDEN DETRAINING ON THE PATELLAR TENDON AND ITS ENTHESIS IN RATS

Background: Different conditions may alter tendon characteristics. Clinical evidence suggests that tendon injuries are more frequent in athletes that change type, intensity and duration of training. Aim of the study was the assessment of training and especially detraining on the patellar tendon (PT) and its enthesis. Methods: 27 male adult Sprague-Dawley rats were divided into 3 groups: 20 rats were trained on a treadmill for 10 weeks. Of these, 10 rats were euthanized immediately after training (trained group), and 10 were caged without exercise for 4 weeks before being euthanized (de-trained group). The remaining 7 rats were used as controls (untrained rats). PT insertion, structure (collagen fiber organization and proteoglycan, PG, content), PT thickness, enthesis area, and subchondral bone volume at the enthesis were measured by histomorphometry and microtomography. Results: Both PG content and collagen fiber organization were significantly lower in untrained and detrained animals than in trained ones (p <0.05 and p < 0.0001). In the detrained group, fiber organization and PG content were worse than that of the untrained groups and the untrained group showed a significantly higher score than the detrained group (p < 0.05). In the trained group, the PT was significantly thicker than in untrained group (p < 0.05). No significant differences in the enthesis area and subchondral bone volume among the three groups were seen. Conclusions: Moderate exercise exerts a protective effect on the PT structure while sudden discontinuation of physical activity has a negative effect on tendons. The present results suggest that after a period of sudden de-training (such as after an injury) physical activity should be restarted with caution and with appropriate rehabilitation programs

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

Augmented reality applied to design for disassembly assessment for a volumetric pump with rotating cylinder

Design for Disassembly (DfD) and Augmented Reality (AR) have become promising approaches to improve sustainability, by providing efficient delivery and learning assets. This study combines DfD and AR to deliver a method that helps to streamline maintenance processes and operator training. It focuses on a common part in the process industry that requires frequent maintenance and repair. DfD was applied to the pump’s design to ease disassembly and reduce material waste, energy consumption, and maintenance time. AR was used to provide an interactive guide to improve the operator understanding of its internal parts and assembly/disassembly procedures. The resulting DfD-AR led to a reduction in maintenance time and shows potential to deliver better training. This highlights the potential of DfD and AR to enhance sustainability, learning, and productivity. The resulting disassembly sequence was taken to an AR simulation, helping process designers to better understand the procedure and further optimize the solution with other constraints

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

Representative volume element (Rve) analysis for mechanical characterization of fused deposition modeled components

Additive manufacturing processes have evolved considerably in the past years, growing into a wide range of products through the use of different materials depending on its application sectors. Nevertheless, the fused deposition modelling (FDM) technique has proven to be an eco-nomically feasible process turning additive manufacture technologies from consumer production into a mainstream manufacturing technique. Current advances in the finite element method (FEM) and the computer-aided engineering (CAE) technology are unable to study three-dimensional (3D) printed models, since the final result is highly dependent on processing and environment parame-ters. Because of that, an in-depth understanding of the printed geometrical mesostructure is needed to extend FEM applications. This study aims to generate a homogeneous structural element that accurately represents the behavior of FDM-processed materials, by means of a representative volume element (RVE). The homogenization summarizes the main mechanical characteristics of the actual 3D printed structure, opening new analysis and optimization procedures. Moreover, the linear RVE results can be used to further analyze the in-deep behavior of the FDM unit cell. Therefore, industries could perform a feasible engineering analysis of the final printed elements, allowing the FDM technology to become a mainstream, low-cost manufacturing process in the near future

Molds with advanced materials for carbon fiber manufacturing with 3d printing technology

Fused Deposition Modeling (FDM) 3D printing is the most widespread technology in additive manufacturing worldwide that thanks to its low costs, finished component applications, and the production process of other parts. The need for lighter and higher-performance components has led to an increased usage of polymeric matrix composites in many fields ranging from automotive to aerospace. The molds used to manufacture these components are made with different technologies, depending on the number of pieces to be made. Usually, they are fiberglass molds with a thin layer of gelcoat to lower the surface roughness and obtain a smooth final surface of the component. Alternatively, they are made from metal, thus making a single carbon fiber prototype very expensive due to the mold build. Making the mold using FDM technology can be a smart solution to reduce costs, but due to the layer deposition process, the roughness is quite high. The surface can be improved by reducing the layer height, but it is still not possible to reach the same degree of surface finish of metallic or gelcoat molds without the use of fillers. Thermoplastic polymers, also used in the FDM process, are generally soluble in specific solvents. This aspect can be exploited to perform chemical smoothing of the external surface of a component. The combination of FDM and chemical smoothing can be a solution to produce low-cost molds with a very good surface finish

Disassembly sequence planning validated thru augmented reality for a speed reducer

The lifecycle of a product is getting shorter in today’s market realities. Latest developments in the industry are heading towards achieving products that are easy to recycle, by developing further technological advances in raw materials ought to include input from End of Life (EOL) products so a reduction of natural harm could be achieved, hence reducing the overall production environmental footprint. Therefore, the approach taken as a design for environment, a key request nowadays in order to develop products that would ease the reverse manufacturing process leading to a more efficient element recycling for later use as spare parts or remanufacturing. The methodology proposed compares three probable disassembly sequences following a comparison of literature-found procedures between genetic algorithms and as a “state space search” problem, followed by a hybrid approach developed by the authors. Time and evaluation of these procedures reached to the best performing sequence. A subsequent augmented reality disassembly simulation was performed with the top-scored operation sequence with which the user is better able to familiarize himself with the assembly than a traditional paper manual, therefore enlightening the feasibility of the top performing sequence in the real world

New methodology for diagnosis of orthopedic diseases through additive manufacturing models

Our purpose is to develop the preoperative diagnosis stage for orthopedic surgical treatments using additive manufacturing technology. Our methods involve fast implementations of an additive manufactured bone model, converted from CAT data, through appropriate software use. Then, additive manufacturing of the formed surfaces through special 3D-printers. With the structural model redesigned and printed in three dimensions, the surgeon is able to look at the printed bone and he can handle it because the model perfectly reproduces the real one upon which he will operate. We found that additive manufacturing models can precisely characterize the anatomical structures of fractures or lesions. The studied practice helps the surgeon to provide a complete preoperative valuation and a correct surgery, with minimized duration and risks. This structural model is also an effective device for communication between doctor and patient