<p>Syftet med detta projekt är att utvärdera ModFix som verktyg och arbetsmetoden för att skaps fixturer med ModFix. ModFix är ett verktyg som är integrerad i Siemens simuleringsmiljön Process Simulate och används för att skapa modulära fixturer. Målsättningen med arbetsmetoden där fixturer skapas med ModFix är att ledtiden och mantimmarna för att skapa fixturer ska reduceras med 50 % i jämförelse med Volvo Cars nuvarande arbetsmetod där fixturer skapas med Catia V5.</p><p>ModFix-verktyget består av tre funktioner. Dessa funktioner är; Configuration Administrator, Fixture Designer och Modular Fixture Mapping Report. Configuration Administrator är ModFix´s administrationsverktyg och används för att skapa de fixturbaser och fixturkonfigurationer som senare används för att skapa modulära fixturer med Fixture Designer. Fixture Designer används för att skapa kompletta modulära fixturer. Modular Fixture Mapping Report är den funktion som används för att generera en rapport som specificerar mappningen mellan de fixturenheterna och de referenspunkter (PLPs/”frames”) där produkten fixeras.</p><p>Fördelarna med arbetsmetoden där fixturer skapas med ModFix i jämförelse med den nuvarande arbetsmetoden är bland annat att fixturen hela tiden befinner sig i samma utvecklingsmiljö och den extra frihetsgraden att roboten simuleras parallellt med att fixturen skapas för att kunna undvika kollisioner. Även att ModFix automatiskt ger förslag på fixturkonfigurationslösningar för att fästa fixturelementen mot fixturbasen och att fixturer som skapas med ModFix är moduluppbyggda av standardkomponenter är två andra fördelar med arbets­metoden där fixturer skapas med ModFix jämfört med då fixturer skapas med den nuvarande arbetsmetoden.</p><p>Resultatet av detta projekt visar att ModFix kan reducera mantimmarna betydligt mer än 50 % för att skapa fixturer jämfört med att skapa fixturer med den nuvarande arbetsmetoden. Ledtiden för att skapa fixturer med ModFix reduceras ännu mer än mantimmarna jämfört med då fixturer skapas med den nuvarande arbetsmetoden där fixturer skapas med Catia V5.</p> / <p>The aim of this project is to evaluate ModFix and its work method used to create fixtures with ModFix. ModFix is integrated in the simulation environment Process Simulate, provided by Siemens. ModFix is used to create modular fixtures. The objective with the work method where fixtures are created in ModFix is to reduce lead-time and man-time with 50 % in comparison with the current work method at Volvo Cars where fixtures are created in Catia V5.</p><p>The tool ModFix consists of three functions. These functions are; Configuration Administrator, Fixture Designer and Modular Fixture Mapping Report. Configuration Administrator is the administration tool in ModFix and is used to create the fixture bases and the fixture configurations as subsequently are used to create modular fixtures with Fixture Designer. Fixture Designer is used to create complete modular fixtures. The Modular Fixture Mapping Report function is used to create a report that specifies the mapping between the fixture units and the reference points (PLPs/frames) where the product is fixed.</p><p>The benefits with the work method where fixtures are created with ModFix in comparison with the current work method includes that the fixture constantly stays in the same development environment and the possibility to simulate the robot in parallel with creating the fixture to avoid collisions. That ModFix automatic gives suggestions of fixture configuration solutions to attach the fixture element to the fixture base and that fixtures created with ModFix are modular built up of standard components are two other benefits with the work method where fixtures are created with ModFix in comparison with the current work method.</p><p>The result of this project shows that ModFix can reduce the man-time significant more than 50 % to create fixtures with ModFix in comparison with the current work method where fixtures are created in Catia V5. The lead-time can be reduced even more than the man-time when using ModFix to create fixtures in comparison with the current work method.</p>

The thesis work is done in collaboration with Prodtex AB, which works to develop digital tools to facilitate the constructor´s work in virtual environments, for instance CAFD within CATIA V5. What the client wanted the project participants to perform was a comparison of the company's semi-automatic software for fixture design, and the traditional construction method with CATIA. The reason for the method comparison is because Prodtex AB requires data, which they can present to potential customers. The participants produced a method to enable the necessary components of the project, the method consisted of training in fixture design, fixture construction and work with the consulting company´s application. These elements have been essential for the comparison to be reliable. The main part of the assignment consisted of constructing units for the given fixture. The reason behind this is due to the necessity of a certain level of experience in fixture design, which is required to be able to assemble units with an accurate and efficient procedure. The method comparison generated data in terms of time in the measurement areas, input, design and export that the project participants analyzed and compiled in the result section. Based on the statistics, participants were able to find answers about which features the software made the most time savings of, and how abundant these were in relation to the traditional design method. A conclusion about when it was beneficial for a company to invest in the software was based on reasoning deduced from the outcome discussion.

The scope of this thesis is the continual development of a wall fixture previously developed ina thesis as a concept together with specification on the final product. The specification from theprevious thesis describe that the wall fixture should meet all required standards for safety, butthe previous existing concept have not been fully developed according to this.The focus of this continuing work has been to see how demands on safety would affect thedesign of the wall fixture. The theoretical framework has therefore been on relevant safetystandards applicable on the Swedish market, and these have been a deciding factor duringdesign choices made during the continuing product development.The methodology has been an iterative work, wherein ideas for development have beendiscussed with Husmuttern, analysed for risks according to demands set by the safety standardsand finally put onto fabrication drawings enable fabrication of a prototype.The conclusion is that it´s possible to minimize risks in the concept phase, but that therequirements on safety makes that some of the demands in the specification have to be omitted.Previous demands on a purely mechanical operation with counterweight is deemed as to riskyfor the users, and a different solution with an electric engine system is chosen instead. This inturn puts demand to follow additional standards regulating the implementation of electronicsand control systems. The risk analysis that have been made should be updated to include thiswhen prototype is built. In conjunction to this the order of assembly of a wall should be chosento eliminate ergonomic risks, and the foundation for the systematic health and environmentwork should be done, two aspects of the health and environment that can’t be fully evaluatedduring concept development. / <p>Bilagor exkluderade i publik version av rapport, efter önskemål från uppdragsgivare.</p>

During circuit board manufacturing, custom fixtures are commonly utilized to ensure quality and to facilitate the operators’ work tasks. Conventionally, these fixtures are manufactured using subtractive manufacturing techniques such as milling. A product development project has been carried out in collaboration with Eskilstuna Elektronikpartner AB (EEPAB), a company that manufactures circuit boards through Surface Mount Technology (SMT) and Through-hole-Technology. The purpose of the study was to investigate possibilities with additive manufacturing (AM) to produce fixtures for use within the company’s circuit board production unit. The used methodology for product development was a modified variant of the generic product development process, focusing heavily on the concept development stages. Data collection was carried out through a literature study as well as meetings and discussions with employees at the case company. A specific circuit board was studied in the project. This circuit board contains through-hole-components that requires the use of fixtures to reliably meet the customer requirements fors oldering. The existing solution was to solder these components by hand, with the use of a custom hand soldering fixture. The components in question are six LEDs as well as a semiconductorpackage. The aim of the project was to provide the company with concept fixtures, designed for additive manufacturing, that enables selective soldering of these components. All prototypes developed in this project have been digital 3D CAD models. This approach was used since nocphysical copies of the circuit board would be available for study within the time frame of the project. Two research questions were designed to aid in reaching the purpose and aim of the study: Research question 1: How can fixtures for selective soldering be designed for additivemanufacturing? Research question 2: What factors should be considered when designing fixtures for selectivesoldering? The project resulted in two new digital fixture concepts, which in theory can replace the hand soldering fixture and enable selective soldering of the components. The results are presented as 3D visualizations along with prepared print files ready for 3D printing, in correct dimensions based on accurately measured Gerber data. The strength of the fixture concepts has been tested in computer simulations where the material was assumed to be isotropic. As a result, the effect of printer settings on the parts’ strength has not been tested. This report also contains recommendations for further research within the subject. Keywords: fixtures, design for additive manufacturing, 3D printing, circuit board manufacturing, selective soldering

<p>Volvo Aeros flygmotortillverkning i Trollhättan har infört ett antal nya detaljvarianter i produktionen. Detta har medfört att den robotcell som är avsedd att utföra en avgradningsoperation är i behov av uppdatering av både hårdvara och mjukvara. Denna rapport följer framtagningen av fixturkoncept som möjliggör att robotcellen kan användas även till de nya detaljerna. De förslag som arbetats fram sträcker sig från enklast möjliga till mer avancerade och nytänkande funktioner. Samtliga funktioner och koncept har genomgått gallringar i ett flertal steg. Förslagen har slutligen kombinerats och poängbedömts med konceptgenereringsverktyg till grund.</p><p>Efter en objektiv poängbedömning av sex olika koncept baserad på concept scoring visar sig två huvudgrupper med tre koncept i varje. Den ena gruppen bygger på en mer avancerad konstruktion med behov av två rotationsaxlar. Dessa medför ett flertal fördelar gällande effektivitet, men även påtagliga nackdelar vad gäller ekonomiska aspekter och idrifttagandetid. Den andra gruppen av koncept baseras mer på det befintliga fixturkonceptet. Detta medför fördelar gällande idrifttagandetid och kostnader.</p><p>Ett huvudkoncept som efter poängbedömningen visat sig mest lämpligt presenteras mer ingående och slutligen förs en diskussion gällande resultatets utfall samt rekommendationer till fortsatt arbete.</p> / <p>Volvo Aero’s aircraft engine manufacturing in Trollhättan has introduced a number of detail models into the production. As a consequence the robot cell dedicated to executing a deburring operation is in need of upgrading of both hardware and software. This report follows the development of fixture concepts that enables the robot cell to be used also for the new details. The proposals that have been developed range from the simplest to more advanced including novel functions. All the functions and concepts have gone through selection in multiple steps. The suggestions have finally been combined and evaluated with concept generation tools.</p><p>After an objective selection based on the concept scoring of six different concepts, the result can be divided into two main groups, each consisting of three concepts. The first group is a more advanced design with a need of two axes of rotation. These three concepts have several advantages when it comes to efficiency, but also obvious disadvantages when it comes to economy and production time. The second group of concepts is based on the fixture existing today. These three concepts are advantageous concerning production time and cost.</p><p>After the scoring process one main concept, judged to be the most suitable is presented more thoroughly. Finally the results as well as recommendations for continued work are discussed.</p>

Volvo Aeros flygmotortillverkning i Trollhättan har infört ett antal nya detaljvarianter i produktionen. Detta har medfört att den robotcell som är avsedd att utföra en avgradningsoperation är i behov av uppdatering av både hårdvara och mjukvara. Denna rapport följer framtagningen av fixturkoncept som möjliggör att robotcellen kan användas även till de nya detaljerna. De förslag som arbetats fram sträcker sig från enklast möjliga till mer avancerade och nytänkande funktioner. Samtliga funktioner och koncept har genomgått gallringar i ett flertal steg. Förslagen har slutligen kombinerats och poängbedömts med konceptgenereringsverktyg till grund. Efter en objektiv poängbedömning av sex olika koncept baserad på concept scoring visar sig två huvudgrupper med tre koncept i varje. Den ena gruppen bygger på en mer avancerad konstruktion med behov av två rotationsaxlar. Dessa medför ett flertal fördelar gällande effektivitet, men även påtagliga nackdelar vad gäller ekonomiska aspekter och idrifttagandetid. Den andra gruppen av koncept baseras mer på det befintliga fixturkonceptet. Detta medför fördelar gällande idrifttagandetid och kostnader. Ett huvudkoncept som efter poängbedömningen visat sig mest lämpligt presenteras mer ingående och slutligen förs en diskussion gällande resultatets utfall samt rekommendationer till fortsatt arbete. / Volvo Aero’s aircraft engine manufacturing in Trollhättan has introduced a number of detail models into the production. As a consequence the robot cell dedicated to executing a deburring operation is in need of upgrading of both hardware and software. This report follows the development of fixture concepts that enables the robot cell to be used also for the new details. The proposals that have been developed range from the simplest to more advanced including novel functions. All the functions and concepts have gone through selection in multiple steps. The suggestions have finally been combined and evaluated with concept generation tools. After an objective selection based on the concept scoring of six different concepts, the result can be divided into two main groups, each consisting of three concepts. The first group is a more advanced design with a need of two axes of rotation. These three concepts have several advantages when it comes to efficiency, but also obvious disadvantages when it comes to economy and production time. The second group of concepts is based on the fixture existing today. These three concepts are advantageous concerning production time and cost. After the scoring process one main concept, judged to be the most suitable is presented more thoroughly. Finally the results as well as recommendations for continued work are discussed.

The aim of this thesis was to investigate if the robotized welding method FSW (Friction Stir Welding) could be applied for joining a rotating structure in an aero engine at Volvo Aero Corporation. FSW is expected to introduce less defects than today’s welding methods and could therefore be suitable for critical aero components. The material is the nickel based alloy Inconel 718, however a material experimentation is outside the scope of this report.The main goal of this study is to verify if the ESAB ROSIO robot based FSW-system has a suitable work space to be able to weld the rotating structure, and if the welding tool has accessibility to the joints. The FSW-process needs a rigid fixture, and a number of fix-ture concepts are presented based on a proposed weld sequence. A final fixture design is proposed, which requires a new design of the structure.The accessibility studies were performed in the robot simulations software Robot Stu-dio. This showed that the robot was unable to weld the proposed model in all areas in the original design. If the robot and the rotating structure can be redesigned the access will be achieved as shown in Robot Studio simulations.In order to be implemented in real production a number of further actions need to be taken and the result of this study can be a basis for these.

Automated Guided Vehicles, AGV:er, används i huvudsak som monteringsplattform inom tung fordonsindustri. En AGV kan användas vid montering av motorer, växellådor och chas-sin. AGV:n transporterar produkten genom en slinga i fabriken, där produkten monteras. Idag säljs AGV:n med ett löfte om femfaldig säkerhet mot brott för alla de ingående komponenter-na. AGV:n är konstruerad för att bära upp en last på maximalt 1800 kg, med säkerhetsfaktorn inkluderad. Lastens tyngdpunkt tillåts ligga en meter ut från infästningen som kopplar sam-man AGV:n med lasten. I arbetet illustreras lasten av en fiktiv motor, som väger 1800 kg med tyngdpunkten placerad en meter ut från infästningen. I detta arbete undersöks om konstruktionen av kopplingen, som kopplar samman motorn med AGV:n, lever upp till utlovad säkerhet. De delar som, i huvudsak, utgör kopplingen mellan AGV och motor är fixtur, kamskiva samt adapterplatta. Fixturen och kamskiva är monterade på AGV:n, adapterplattan monteras temporärt på motorn. Adapterplattan har tre klackar som sammanlänkar den med fixturen. För att avgöra hur väl kopplingen lever upp till femfaldig säkerhet mot brott, kartläggs de krafter som verkar i kopplingen. Dessa krafter ligger till grund för de FE-analyser som utreder kopplingens spänningsfördelning. Utifrån FE-analyser och analytiska beräkningar av kopp-lingen bestäms hållfasthetsegenskaperna. Kopplingens komponenter har, generellt, goda hållfasthetsegenskaper som lever upp till fem-faldig säkerhet mot brott. Resultaten visar att vissa komponenter har tiofaldig säkerhet mot brott vid belastning med den 1800 kg tunga motorn. Dock visar beräkningar av skruvför-banden i kopplingen på brister som bör åtgärdas. Skruvförbanden i fixturens klackar understi-ger de krav, som baseras på säkerhetsfaktorn. Under förstudien uppdagas det att fixturen, på vissa AGV:er, monterats med skruvar med lägre hållfasthetsklass än vad som står angivet på ritningsunderlaget. Detta medför en allvar-ligt sänkt säkerhet för kopplingen. Orsaken till att fel skruvar använts är inte känd. Ett arbets-sätt för att förhindra fel skruv vid montering bör finnas. I arbetet studeras Arbetsmiljöverkets föreskrift ”AFS 2008:3 – Maskiner” vilken har legat till grund vid val av säkerhetsfaktor för konstruktionen. Utifrån studien av AFS 2008:3 genom-förs ett försök till att tolka den säkerhetsfaktor som gäller för kopplingen. Resultaten av denna rapport kan ligga till grund för ett fortsatt arbete, då en vidareutveckling av kopplingen blir aktuell. / Automated Guided Vehicles, AGV´s, are mainly used as a mounting platform in the heavy vehicle industry. An AGV is commonly used in the assembly process of; engines, gearboxes and chassis. The AGV transports the product through a predefined trail in the plant where the product is mounted. Today the AGV is being sold with a promise, from the manufacturer, that the construction is engineered with a safety factor five, against fracture, for any component in the AGV. It is engineered to support loads to a maximum of 1800 kg, with this safety factor included. The center of gravity is allowed to be one meter out from the mount that connects AGV with the supported load. This work investigates if the coupling, which connects the supported engine with the AGV, meets safety requirements. The coupling consists three main parts; fixture, cam-disk and an adapter plate. The fixture and cam-disk is mounted on the AGV, and the adapter plate is tem-porarily mounted on the engine. The adapter plate has three so called “heels” that links it with the fixture. To determine how well the coupling meets the safety requirements, the forces acting in the structure, while the AGV is loaded, is calculated. The work load is illustrated by a fictional engine, weighing 1800 kg with its center of gravity placed one meter out from the mount. These forces form the basis for the FE-analyzes, investigating the coupling strength proper-ties. Knowing the couplings strength properties, conclusions if the coupling meets the safety requirements can be adopted. The coupling component has, in general, good strength properties that meet the safety re-quirement of five-times security. The results show that some components have tenfold safety, while the AGV carries a load of 1800 kg. Calculations show that the screw connections of the fixture don’t meet the safety requirement and needs to be further investigated. The pilot study revealed that the fixture, for some AGVs, has been assembled with wrong screws. Instead of 10.9-screws, 8.8-screws were used. This leads to a serious consequence of reduced security for the construction. The cause of why fault screw was used is not known. One approach to prevent wrong screw is highlighted as suggestions for improvement. To understand why such a high security factor as five is chosen, the regulations “AFS 2008:3 – maskiner” that formed the basis for selecting the safety factor is studied. The study has been a basis for the conclusions for this work. The results of this survey may serve as a basis for further work, when further development of the coupling is relevant.

This study focuses on providing innovative solutions to assist workers lacking technical knowledge at Husmuttern AB to assemble its products. The Swedish company produces standardized building-sections that can be assembled to build model-houses, and other forms of buildings in mobile factories. The company’s vision is to provide opportunities for inexperienced labors and newcomers to Sweden, and so playing a positive role in integrating immigrants into the Swedish market and society. To actualize this ambition, this paper aims specifically at developing tools/products that assist unskilled workers to reduce the margin of errors in determining where and how the screws will be placed when combining the wooden beams and plywood boards, which form the building sections.   Semis-structured interviews with workers at Husmuttern AB were conducted to identify problems associated with the working process. Ullman’s product-developing method was employed to develop the facilitative tools. Several concepts were developed and compared in an attempt to find the best solution for the given problem(s), and eventually two proposed products were presented: the first is a template where holes are located to mark where the screws should be placed. The other product is basically an inclined plane with a drill-guide to direct the screw in the correct gradient and prevent the screw from moving through the process.

Arbetet är ett utredningsarbete som går ut på att försöka lokalisera felkällor och göra förbättringar på en testutrustning som mäter rodervinklar på akterdelen på en robot. Rapporten innehåller en översiktlig bild över den tidigare metoden och dess felkällor som hittas vid test av den tidigare metoden. Utredningen utmanar också många utav antagandena som är gjorda för beräkningarna av den tidigare metoden. Detta utförs för att kunna bekräfta eller dementera antagandena. Detta görs i form av matematiska modeller som testar olika delar av metoden. Varje del i rapporten består av en beskrivning av vad kapitlet avser följt av felkällorna som upptäckts i metoden när den testas i modellen. Det framtagna metodförslaget utsätts samma prövning som den tidigare metoden för att utreda skillnaderna. I resultatet kan man se de slutsatser som dragit av varje del av utförandet. / The task is an investigation to try and locate errors and make improvements on a test equipment that measures rudder angles on the rear-end of a robot. The report contains an overview of the previous method and the errors that is found by testing it. The investigation also challenges many of the assumptions made when the previous method was made. This was made in order to either confirm or deny the assumptions. This is done by the use of mathematical models to simulate different parts of the method. Each part of the report consists of a description of the section followed by explaining the discovered errors that was found by testing the method in the models. The new produced method suggestion is exposed to the same tests as the previous method to discern the differences. The conclusions made from the sections can be found in the results.