Multiple metal blank centering: Concept development for production
2023 (English)Independent thesis Advanced level (professional degree), 20 credits / 30 HE credits
Student thesis
Abstract [en]
This project has delved into the needs, specifications and solutions to a concept which automatically centers multiple metal blanks with a high tolerance for overlap resistance spot-welding. As future design of chassis structures shifts to larger linked patchworks such as door rings and floor assemblies there is new demand for smarter and faster production techniques. One area in need of evolving is the spot-welding process of linking multiple parts of “giga stamps” which requires precise placement of every blank with high production rate. The product development process was early chosen to be a configuration of Ulrich K. and Eppinger S. product development guide which is the basis for all steps in this project. During the project the effects of welding deformation, unwanted welding effects and stress relaxation has been researched to avoid unseen consequences during concept testing in future work. By identifying needs and requirements for the centering method from multiple departments at Gestamp Hardtech Lule ̊a 78 unique needs were found, ranked and converted to a product specification that was compared with solutions already on the market. Five concept generation sessions with three brainstorming methods resulted in 147 different concepts that have been screened, combined and scored to refined theoretically working solutions. Every concept has been evaluated and graded in increasing levels of detail in five different evaluation matrices leaving nine primary candidates. In an informed decision with the help of six experts’ opinions and comparisons of advantages and disadvantages with each candidate, the concept with laser triangulation was chosen as the winning concept with a newton table as a secondary option. The foremost advantages were time saving, low complexity, long lifetime and easy maintenance. If the solution would be applied and compared with today’s production in Gestamp Hardtech Lule ̊a’s welding cell the time save could be 20 seconds per blank and requires one less robot in the cell. Future work includes concept testing and fixture-/referencing system development.
Place, publisher, year, edition, pages
2023. , p. 96
Keywords [en]
Product development, Production development, LEAN, Manufacturing, Fixture, Fixture development, Improving production, A3, Production processes, Production technology
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
URN: urn:nbn:se:ltu:diva-98823OAI: oai:DiVA.org:ltu-98823DiVA, id: diva2:1774135
External cooperation
Gestamp Hardtech
Subject / course
Student thesis, at least 30 credits
Educational program
Mechanical Engineering, master's level
Supervisors
Examiners
2023-07-042023-06-252023-07-04Bibliographically approved