engcon® är ett företag som arbetar med produktutveckling. Företagets mest lönsamma produkter är tiltrotatorer, vilket kan beskrivas som en handled för grävmaskiner. Syftet med detta arbete var att ta fram ett alternativt koncept för skyddshuv till tiltrotator EC209, då den nuvarande lösningen erhållit klagomål kring variationer och inre spänningar till följd av tillverkningsmetoden. Företaget är även intresserad av en reducerad kostnad och mer slimmad design. Målet var att ta fram ett mer användarvänligt och kostnadseffektivt koncept samt testa mot produktion. Produktutvecklingsprocessen bestod av en nulägesanalys, där kartläggning av nuläget genomfördes. Datainsamling från intressenter som bestod av tillfällighetsurval och deltagande observation. Genomförandet av en litteratursökning för att erhålla information om stål- och polymermaterial samt tillverkningsmetoderna formsprutning och bockning. Datainsamlingen användes för att samla relevanta kriterier och upprätta en produktspecifikation. Utifrån funktionella kriterier generera koncept med en kreativ och systematisk metod där syftet var att erhålla en mängd dellösningsalternativ. Därefter med en morfologisk matris skapa totallösningsalternativ. Val av koncept med hjälp av elimineringsmatris och relativ beslutsmatris. Avslutningsvis genomgå processfasen konfiguration och detaljkonstruktion för framtagning av iterationer och slutgiltigt koncept. Resultatet av detta arbete utmynnades i framtagning och presentation av ett koncept som erhåller delfunktion för att underlätta montage tillsammans med en design avsedd för tillverkningsmetoden, vilken möjliggör minimerade variationer vid tillverkning. Additivt tillverkade iterationer för att testa mot produktion tillsammans med en kompletterande kostnadskalkyl för framtagning av dessa och uppskattad kostnadskalkyl för formsprutning utifrån tät dialog med leverantör Målet med arbetet kunde uppfyllas då studien resulterade i ett slutgiltigt koncept med delfunktion för att underlätta montering och ett reducerat styckpris mot den nuvarande lösningen. / engcon® is a company that works with product development. The company’s most profitable products are tiltrotators, which can be described as a working arm for excavators. The purpose of this work was to develop an alternative concept for a protective hood for tiltrotator EC209, as the current solution has received complaints about variations and internal stresses because of the existing manufacturing method. The company is also interested in a reduced cost and slimmer design. The goal was to develop a more user-friendly and cost-effective concept and test it against production. The product development process consisted of a current situation analysis, where mapping of the current status was carried out. A data collection from stakeholders consisted of opportunity sampling and participant observation. Literature search was carried out to obtain information on steel and polymer materials as well as the manufacturing methods including injection molding and bending. Data collection was implemented to gather relevant criteria and establish a product specification. Based on functional criteria, concepts were generated using a creative and systematic method with the aim of obtaining a number of particular solution alternatives. Then with a morphological matrix good solution alternatives were suggested. Choice of concept was done using elimination matrix and relative decision matrix. Finally, the suggested final concept was configured and detailed construction of final concept was reached through few iterations. Present work resulted in the development and presentation of a concept that facilitates assembly together with a design intended for the manufacturing method, which enables minimized variations in manufacturing. Additively manufactured iterations to test against production together with a supplementary cost calculation for the production of these designs and estimated cost calculation for injection molding based on close dialogue with the supplier were carried out. The goals of the work are met and a final concept helping easier assembly and having a reduced unit price compared to the current solution is presented.

This thesis has attempted to reduce costs associated with wear parts in test equipment at Ericsson’s master and industrialization center (MIC) in Kista. Two different cases have been pursued, and each has been designed to follow a, for the purpose, adapted version of the design research methodology (DRM). The adapted model was presented and its use in both cases was additionally evaluated. Both cases were based on products that already have been launched and are used in production. In order to avoid expensive changes to surrounding equipment, incremental product development was chosen in both cases. The first case focused on test equipment used in the production of digital units for radio base stations. After the wear parts of this test equipment were examined, it was found that a plastic detail was manufactured through milling and as a result was quite expensive. The plastic detail was redesigned so that it could be manufactured using the injection molding process instead. This resulted in an estimated cost reduction of 48 %. The second case focused on wear parts of test fixtures used in the production of radio filters, also used in Ericsson’s radio base stations. A more process-oriented view was adopted in this case and parameters believed to be causing added wear such as positional and angular misalignment were examined further. Tolerance chains for each wear part in the assembled test fixture were calculated to determine the degrees of possible misalignment. The resulting data did however not correlate with each wear part’s individual wear interval, and no concrete cost reductive improvements could be delivered. Instead suggestions which can lead to further cost reductions in the long term were presented. The model used to develop improvements for these two cases was found to have helped the process in both cases, however further research of this model is recommended in order to determine if it is suitable for these types of projects in general

Sensor technology has played an essential role in improving the observability in manufacturing processes and providing input to enabling more effective and efficient product and process design. To analyze an injection molding process, pressure and temperature variations have shown to be the most critical factors that affect quality in the molded parts. The state of sensing in the industry utilizes separate and wired sensors placed away from the mold cavity to measure these parameters, and holes have to be drilled through the mold steel to accommodate the wires. To minimize mold structural modification, which is time consuming and expensive, it is desired to design a miniaturized sensor module that can be structurally embedded into the molding cavity and simultaneously measures the two parameters (i.e. a dual-parameter sensor) in real time, during the molding process. This thesis presents the structural optimization of the sensor and development of a new Fluid-Structure algorithm to analyze the performance of the sensor as in an actual injection molding cycle. Thus, research involves three key tasks. Given a required mold steel thickness, an optimization problem was solved analytically with outer diameter, thickness and number of rings as variables under the maximum allowable pressure and minimum required energy constraints to achieve a minimum volume of the piezo stack. As it is infeasible to test the sensor with different dimensions under the flow to understand its behavior under high pressure and temperature polymer melt, the development of a numerical model is required. A mold-melt interaction algorithm is developed to have a mold-melt interface using finite element analysis, analogous to an injection molding process. The model showed the change in state of polymer melt and its effect on cavity due to change in viscosity with the change in temperature. The model validated the energy output of the optimized sensor when the temperature and pressure of polymer changes and the effect of these parameters on mold and sensor. The voltage output and temperature results were compared with analytical solution. The numerical results of voltage output matched within 0.1% and temperature results matched within 3% of the analytical solutions. Finally a test bed was fabricated to simulate and reconstruct the pressure profile obtained from the numerical model to study the actual output from a fabricated sensor. The aim of the test bed was to reconstruct pressure profiles obtained from numerical simulations to investigate the sensor output from the fabricated injection molding sensor. The test bed evaluated the output from sensor as can be observed in actual injection molding machine. Comparison of the injection molding sensor with a piezo-resistive sensor showed good agreement.

京都大学 / 新制・課程博士 / 博士(工学) / 甲第24642号 / 工博第5148号 / 新制||工||1983(附属図書館) / 京都大学大学院工学研究科化学工学専攻 / (主査)教授 大嶋 正裕, 教授 竹中 幹人, 教授 佐野 紀彰 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DFAM

京都大学 / 新制・課程博士 / 博士(工学) / 甲第24647号 / 工博第5153号 / 新制||工||1984(附属図書館) / 京都大学大学院工学研究科化学工学専攻 / (主査)教授 大嶋 正裕, 教授 佐野 紀彰, 教授 山本 量一 / 学位規則第4条第1項該当 / Doctor of Philosophy (Engineering) / Kyoto University / DGAM

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This study focuses on the cycle-averaged mold temperature of additively manufactured injection molding tooling and how it is affected by conformal cooling channels. This was done by producing a benchmark mold out of Digital ABS produced by Stratasys, an acrylic based photopolymer, which was then used to produce injection molded parts until tool failure. Another, more cost-effective material, High Temp Resin produced by Formlabs, another acrylic based photopolymer, was also tested but yielded very little success. Then the mold design was altered by adding conformal cooling channels and again tested by producing injection molded parts while tracking the mold temperature. This experimentation was then compared to an injection molding cooling channel model in order to validate the model for use with additively manufactured tooling with conformal cooling channels for use in injection molding. The benchmark Digital ABS mold was able to produce 66 shots in the injection molding machine before complete mold failure. The Digital ABS mold had a cycle-averaged mold temperature of about 155°F. The High Temp Resin mold was able to produce 3 shots before complete mold failure. The High Temp Resin material is much more brittle, and the mold design did not take into account how brittle the material was. The Digital ABS mold with conformal cooling channels had a cycle-averaged mold temperature of 111°F. This is significantly lower than without cooling channels and has a high potential for improving tooling life. The cooling channel model predicted the cycle-averaged mold temperature to be 116°F. This proved to be a very good model and can be used as a design tool when choosing cooling channel geometry and position in additively manufactured tooling. This research shows the potential that conformal cooling channels have to help improve additively manufactured tooling life for injection molding. As shown in other research done, the ability to maintain the mold below 120°F significantly improves the life of additively manufactured tooling. The results of this study demonstrate the effectiveness of conformal cooling channels in controlling mold temperature. It should be researched further, but the use of conformal cooling channels has the potential to produce more production or prototype parts with additively manufactured tooling for injection molding.

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