This report presents a thesis work on advanced level in the course PPU502 – Product development. The thesis work has investigated the outcome of applying the Product Development Process in the development of a production system, through a case study at Munters Europe AB. The case study aimed to examine, map, analyze and develop a manufacturing process that currently consists of manual and time consuming operations. The purpose of this thesis was to investigate the versatility of the knowledge obtained during the MSc program Innovation and Product Design, as a result of the markets expectations of engineering graduates to be generalists with good ability to apply their skills in more than one area. The methodological approach in this thesis is based on the research process that Kothari (2004) presents and are modified in to 4 phases. Phase 1 defines the project and establishes research questions that are used as guidelines for the work. Phase 2 includes the case study, where the Product Development Process was implemented in the development a manufacturing process. Phase 3 consists of data collection, where quality assuring and general methods for developing production systems were identified. Phase 4 compares the empirical results from the case study with the collected data, describes differences of the methods and analyzes the outcome. / Denna rapport presenterar ett examensarbete på avancerad i kursen PPU502 – Produktutveckling. Examensarbetet har undersökt utfallet av att tillämpa produktutvecklingsmetoder vid utveckling av ett produktionssystem, genom en fallstudie vid Munters Europe AB. Fallstudien syftade till att granska, kartlägga, analysera och utveckla en tillverkningsprocess som, i dagsläget, består av en del manuella operationer. Syftet med examensarbetet var att undersöka mångsidigheten av den erhållna kunskap från civilingenjörsutbildningen Innovation och Produktdesign då marknaden förväntar sig att civilingenjörer ska vara generalister med god förmåga att tillämpa sin kompetens på fler än ett område. Metodiken i detta arbete grundar sig i forskningsprocessen som Kothari (2004) presenterar och är modifierad till 4 faser. Fas 1 definierar projektet och upprättar frågeställningar som sedan styr arbetet. Fas 2 innehåller fallstudien, där produktutvecklingsprocessen har följts för att utveckla en tillverkningsprocess. Fas 3 består av datainsamling där kvalitetssäkra, allmänna metoder för utveckling av produktionssystem har identifierats. Fas 4 jämför empirin från fallstudien med de insamlade data och redogör skillnader samt analyserar utfallet.

Abstract: This thesis work was a part of Halmstad University’s Mechanical Masterprogramme curriculum done in favour of ABB Alingsås. Our industrial partnerproduces and manufactures low voltage electrical distribution cabinets, connectorsand switch gears. This project is focused on specific electrical connector used inABB’s trademark cabinets. These electrical connectors serve as both the input and output points for thedistribution cabinets. The product under scope is an extension connector calledADI3M which is used in conjunction with the large sized cable connectors(AD300). This is a sequential design optimization activity performed after theredesigning of the AD300 to ensure interface compatibility and also aimed atopportunistic cost reduction. The ADI3M should provide design compatibility withboth old and new AD300 connector designs along with the comfortable interfacinginside the CDC and SDC cabinets. With the design process and concepting knowledge gained from the course work inHalmstad university along with the ABB’s industrial exposure towards the powersupply networks we proposed four different design concepts. These design conceptswere then evaluated against interface compatibility, cost aspects, manufacturingreadiness, mechanical strength, heat generation and electricity conductionproperties. Among the product development techniques, we applied QFD processto generate the concepts, waterfall method to frame the engineering design processflow and morphological matrix to select the generated concepts. We then changedthe raw material from brass to aluminium and extrusion process due to its beneficialproperties compared to brass and copper with various other reasons explainedclearly in the thesis content. For the plastic cover we preferred poly-carbonate dueto requirements such as transparency, stiffness, etc. Two of the best feasibleconcepts were selected and the design proposals were prototyped using 3D printingtechnology. The 3D printing method used was fused deposition modelling (FDM).Later machined aluminium prototypes were then produced for the metalsubcomponents to do real time strength analysis and interface checks. Weperformed a theoretical product strength analysis using ANSYS19.2. Then resultswere then evaluated, and the final concept was chosen according to the factors suchas cost impact, easy installation and comfortable inter-component clearance.Finally, the prototypes were tested for IP rating fulfilment and compatible interfaceswith adjacent components. The consecutive activities to be done out of thesis scope is to conduct mechanicaland tests and record the performance. The future scope of this project is to developa hybrid design combining the AD300 and ADI3M connectors which would enableeasy product handling, simplified functionality and further reduce cost.

The shooting sport is one of the most widespread sports in the world and it is being practice in most countries. Based on their own experiences, in competition - and hobby shooting, the client M4Solutions found a demand and need for a shooting target that is manufactured in Sweden. The purpose of the project has been to develop, with the help of Marcus Walldén, two shooting targets from idea to finished product. These two shooting targets, Plate Rack Target and Dueling Tree, would each be equipped with a mechanical resetting system but will in the future have the ability to be provided with an electronic resetting system. The project from the client was divided into two theses. One of these two, written by Marcus Walldén, focused on the tripod parts and the overall design work for both Plate Rack Target and Dueling Tree. The thesis that is presented in this report have focused on resetting systems, the design of protective plates and other peripherals for both shooting targets. This work has primarily been in CAD environment where design, construction and development has been given free rein. Calculations, test shootings and choice of materials has been made in order to reach the best possible solutions. The thesis resulted in two complete 3D models and two full-scale prototypes of steel.

<p>Windy Scandinavia is the manufacturer of the luxury yacht Windy 52 Xanthos. There is a storage application in the aft sofa on the boat that doesn’t live up to the standard and functionality level that Windy represents. This report describes the mechanical design process of this storage application, which currently has bad functionality and is expensive for Windy in production.</p><p>The aim of the project was to develop the existing storage application to a low cost application. Simple and effective for Windy to produce and assemble, with the directives of access to the front or from above to the sofa.</p><p>A feasibility study of the existing application was made to get a picture of disadvantages and advantages to keep for further concepts.</p><p>The concept development included three steps; each step implied further development in level of detail. Starting with a range of concepts covering all different possibilities of access to the storage space, and ending up with a couple of concepts developed in detail with costs and knowledge of productions methods.</p><p>The result became a standard application; a hatch with gas dampers. The reasons why this became the result was because of the low cost, simplicity and functionality. Small modifications of existing moulds and no new components or production methods needed.</p><p>Conclusion of the result is that it fulfils the requirement specification and thereby is a proper result. The conceptual design phase generated many different concepts, from these concepts a result satisfying the requirements emerged.</p>

Windy Scandinavia is the manufacturer of the luxury yacht Windy 52 Xanthos. There is a storage application in the aft sofa on the boat that doesn’t live up to the standard and functionality level that Windy represents. This report describes the mechanical design process of this storage application, which currently has bad functionality and is expensive for Windy in production. The aim of the project was to develop the existing storage application to a low cost application. Simple and effective for Windy to produce and assemble, with the directives of access to the front or from above to the sofa. A feasibility study of the existing application was made to get a picture of disadvantages and advantages to keep for further concepts. The concept development included three steps; each step implied further development in level of detail. Starting with a range of concepts covering all different possibilities of access to the storage space, and ending up with a couple of concepts developed in detail with costs and knowledge of productions methods. The result became a standard application; a hatch with gas dampers. The reasons why this became the result was because of the low cost, simplicity and functionality. Small modifications of existing moulds and no new components or production methods needed. Conclusion of the result is that it fulfils the requirement specification and thereby is a proper result. The conceptual design phase generated many different concepts, from these concepts a result satisfying the requirements emerged.