This thesis consists of a detailed analysis of different blade testing methods and improvements to a novel concept for tri-axial testing of large wind turbine blades. As the blades are one of the most critical components of the wind turbine, they have to be tested in order to ensure that their specifications are consistent with the actual performance of the blade. It must be demonstrated that the blade can withstand both the ultimate loads and the fatigue loads to which the blade is expected to be subjected during its design service life. There are basically two types of blade testing: static testing and fatigue testing. Testing of the blades statically and dynamically helps in improving the designs and the manufacturing processes. This thesis has two objectives. The first objective is to document the assumptions, calculations and results of an initial sizing of a bell crank system for testing blades 50m, 60m and 70m long. The second objective of this report is to document the modeling of one of the alternatives to bell crank system in SolidWorks. The thesis ends with conclusions and suggestions for future work. An advanced blade testing method which can be used for large wind turbine blades is developed and so are the system requirements. The concept is used to excite the blade in flapwise and edgewise direction simultaneously. The flap motion of the blade is caused by BREX resonant technology, which is already used by National Renewable Energy Laboratory (NREL) in Colorado, and edgewise motion is delivered by the use of two inclined hydraulic actuators and linear guide rail system is used to move the inclined actuators in the flapwise direction along the blade motion. The hydraulic system and linear guide rail requirements are analyzed and discussed. The design is discussed and analyzed in detail proving it to be feasible. The cost estimation is done for the design. It is recommended for implementation as it will serve as an efficient way of testing large wind turbine blades.

The market for large-scale solar parks is growing rapidly. The Swedish government has set goals to incorporate a larger amount of renewable electricity in the Swedish energy mix. To achieve this, new solar parks are being built in various locations throughout Sweden. Within these projects there are some tasks which take longer than others, and finding a suitable location is one of them. Sweden has a lot of forests and building solar parks in these, in an efficient way could expand the options for where and how the parks can be built.The purpose of this thesis was to develop a conceptual machine which could be used in the construction of solar parks in forests or other terrains that are considered “tougher” than the fields where solar parks are traditionally built today. The research question which this paper is based on is: “How can a solar panel mounting structure be designed to lower assembly time?”. This question is answered throughout this paper, but it should be mentioned that this project started with two different questions which aren’t of great importance, but they are mentioned in a suitable place in the paper.The theoretical framework presents the method that this thesis follows. It is a product development method created by Ulrich and Eppinger (2014), which is easy to follow and adapt to specific projects. The approach describes how the work was conducted. One notable difference that this project experienced compared to the generic product development process was that there was very little information available in online articles, scientific reports, or books regarding the research questions. This led to most of the information on which the work was based coming from interviews with key individuals from companies experienced in similar projects. The result of the work was a conceptual structure aimed at reducing assembly time. This was achieved by integrating the same functionality as the existing structures, in fewer components. The concept involves assembling a frame and attaching four panels to it, which are then delivered as a module to the site for installation. The result consists of two versions of this concept, one where the structure stands on one leg, and the other using the same frame but standing on two legs. The research question was answered by the group as the result shows a concept where certain components are prefabricated before being delivered to the installation site, reducing the time to perform certain tasks on-site.

For several hundred years there has been a great deal of emphasis on how industries and businesses may encourage excellent production work that does not harm the environment or the working individual. NKT is a world leader company in cable technology and designs, manufactures, and installs voltage cables. The company includes a department where splicing is performed on cables to extend or repair them. To complete the splicing process, however, the inner most structures of the cable must first be cleaned from a substance called compound. Today, this cleaning process is carried out manually by the workers. Despite the efficient operation of NKT's splice department, various risks have been identified that might have a negative impact on both the worker and the environment. On one hand, there is a risk that the cleaning agent containing a certain amount of unhealthy chemicals will encounter the worker and cause health risks, and on the other hand, chemical leakage may occur on the work surface, resulting in a contaminated work area, and unnecessary material waste. This material waste also adds to less cost-effective operations, since bigger amounts will be required to accomplish the intended work, this in relation to the fact that the process requires a considerable time. Thus, the aim of this degree project is to investigate if streamlining the procedure of cleaning the compound from the conductors in high voltage cables before splicing is possible by developing a mechanical device or replacing the current used solvent or both. The methods used for this project were a combination of the design thinking strategy and participatory action research and to deeply understand the methods, a literature review was also performed. The results obtained were a well-detailed virtual simulation in SolidWorks, a functional alpha prototype, and results from a conductivity measurement for PF-Solvent and Strovels Smådelstvätt 100. Although the first laboratory tests showed equivalent effects for PF-Solvent and Strovels Smådelstvätt 100 regarding the solubility of the compound, PF-Solvent's good conductivity properties wereconfirmed while Strovels Smådelstvätt 100 proved not to be suitable for this cleaning procedure due to the big difference in the values. The results obtained from the sustainability template provided the project with useful guidelines for refining the concept into a long-term solution. Many of the components of the physical product will be built from stainless steel, which will make it simpler to recycle at the end of its useful lifespan. In conclusion, it requires a development of a device that cleans the conductor from the compound. The device / machine can keep the solvent in a special place and at the same time, the worker has more control over how much solvent is used. According to the laboratory tests, the solvent Strovels Smådelstvätt 100 had an equivalent effect on the compound during the same time interval as PF-Solvent. It was also milder from the environmental and health aspects. Furthermore, the development of a mechanical device can contribute to reduced waste of various materials, such as brushes, gloves, and spray bottles, during the procedure. Finally, investing in such a machine can be expensive, but in the long run this investment leads to savings in materials used today. However, a machine procedure involves a large transition that requires a lot of time, resources and planning as it shall be developed through collaborations with different industries.

Topology Optimization is a lightweighting method based on finite element analysis that produces a part with optimum material distribution in the design space. Results from topology optimization often have organic shapes and curves that are difficult if not impossible to machine with traditional subtractive manufacturing methods. This paper analyzes the implementation of the Solidworks® Topology Optimization add-in into the mechanical design process and discusses required postprocessing to ensure manufacturability of the optimized part though a case study on two example parts. Results of traditional optimization, topology optimization and “selective” optimization (optimization using the results from topology optimization to selectively remove material to ensure manufacturability) were compared in terms of weight reduction and time required for optimization. In addition, simplified lightweighted parts were experimentally tested to validate the results of Solidworks® FEA and Topology Optimization to ensure physical part performance and increase confidence in future model results. Overall, it was determined that due to the large amount of time to setup and run, topology optimization may not be the most effective lightweighting method if time is a significant design constraint. However, for some specific applications where part weight is of major importance or where additive manufacturing may be a possible manufacturing process, the benefits of topology optimization’s material removal capability outweigh the required solution time.

This thesis looks at the development of a physical 3D learning model designed to introduce key stage 3 students to the basics of SolidWorks with the ultimate aim of developing the model to a level where schools can use it in the education of students. The purpose of this thesis is to identify any problems with the author’s final year undergraduate project (a three-dimensional card model of Tower Bridge, which features instructions to help teach the fundamentals of SolidWorks), and to create a new learning material based on those findings. The creation of the new learning material was in part based on feedback during visits to local secondary schools. Small scale user trials were also conducted throughout the product development in order to gain first-hand insight into how the solution was meeting its objectives, i.e. being a viable learning pack for Secondary Schools. The overall project aim was to create 3 – Dimensional teaching material designed to assist in classrooms for secondary education. This aim was partially realised in that a clear and concise learning path was created. However, due to lack of engagement from local secondary schools it was not feasible to conduct user trials. These trials and subsequent review have been suggested as possible future work. It should be noted that apart from the Tower Bridge product, reviewed in chapter 3, all work presented within this thesis was conducted as part of this master study.

No description available.

As environmental impact and environmental emissions are an important part of today's society, due to climate change, high demands are placed on material selection, how the product is recycled and how the product is remanufactured. Remanufacturing is by definition to manufacture an old product into a new product Remanufacturing is an important process to get a sustainable life in the industries, this is because of the increased consumption of products and technique that are thrown away near the products end-of-life. Remanufacturing is a process applied to a product or a part near its end-of-life to transform a used product to a like-new product. At present, remanufacturing is a process that is not used as much in the marine world as other transportation industries, such as automotive and rail. At present, the remanufacturing process is only applying on smaller structures such as engines, propeller shafts, compressors and pumps.  This project work aimed to investigate the effects of implementing remanufacturing into Onmar products. In order to study how remanufacturing affects a company, an analysis was carried out on the company's Rail actuator to study the effects of implementing remanufacturing into the product. Since there are high demands on how the product is designed, an analysis was carried out on how the rail actuator was designed to meet the criteria set. This resulted in two different covers being produced in order to meet the requirements needed to carry out remanufacturing on the product. By implementing remanufacturing on the rail actuator resulted in large savings on energy consumption, material recycling, manufacturing costs, raw materials and carbon dioxide emissions when manufacturing new material.

To prevent damage to the cabin crew an optimal coffee- and teapot in a number of aspects in airline catering was developed, so called “SAS-kannan”. It was launched in 1980 and has been manufactured in over 300 000 copies, which has worn out the mold and it is in need of replacement. The mold is advanced and it will be expensive to manufacture a new one. August Lundh who is the manufacture of “SAS-kannan” today, want to develop a new product for serving drinks with a cost-effective manufacturing. It should involve the positive qualities on the “SAS-kannan” and be adapted to today's airline catering. The objective of the thesis was to develop an ergonomic and functional product for serving cold drinks with cost-effective production and the adaptation to today's storage trolleys on aircrafts. The research began with a comprehensive theoretical framework consisting of scientific articles and academic approved books. Interviews were made to complement the theoretical framework and primary data was collected. All the gathered information was examined in the next step to ensure the validity and reliability. A case study was conducted at August Lundh by a product development that was based on the examined information. To do more detailed tests 3Dprintings were created of each development. The result was a pitcher that is designed to enable an uncomplicated and ergonomic use. It is also adapted for efficient and stable storage in the ATLASboxes, easy filling of the beverage and washing. The pitcher holds 1.5 liters and is a perfect combination of the number of servings, refills of the pitcher and a low weight. The pitcher is made with injection molding and is made out of the Bisfenol A free plastic Tritan. The grip is designed to give the pitcher an ergonomic use for different sized hands and it is symmetrical to allow equal use of both left and right handed. The spout provides a controlled and even beam, and a drip free serving by cutting the beam properly. The spout is designed so that the pitcher only needs to be tilted 90 degrees from an upright position to be emptied. The lid is a separate part which is put on the pitcher with press-fit and it helps to control the beam during serving and to prevent spills in case of turbulence. The authors believe that the objective has been accomplished by a thorough theoretical framework and an empirical study through interviews and a case study. / För att förhindra skador på kabinpersonal utvecklades SAS-kannan som var en optimal kaffe- och tekanna i ett flertal aspekter inom flygcatering. Den lanserades på 1980-talet och har idag tillverkats i över 300 000 exemplar vilket har medfört att formverktyget blivit slitet och är i behov av att bytas ut. Det befintliga formverktyget är avancerat och det blir dyrt att tillverka ett nytt. August Lundh som idag tillverkar SAS-kannan vill därför utveckla en ny produkt för servering av dryck med en kostnadseffektiv tillverkning. Den ska kunna jämföras med SASkannans positiva egenskaper och vara anpassad för dagens flygcatering. Syftet med examensarbetet var att ta fram en ergonomisk och funktionell produkt för servering av kall dryck med kostnadseffektiv tillverkning samt anpassning till dagens förvaring i serveringsvagnar på flygplan. Forskningsprocessen påbörjades med en omfattande teoretisk referensram bestående av vetenskapliga artiklar och akademiskt godkända böcker. Intervjuer gjordes för att komplettera den teoretiska referensramen och primärdata samlades in. All insamlad information granskades i nästa steg för att säkerställa validiteten och reliabiliteten. En fallstudie utfördes hos August Lundh i form av en produktutveckling som var baserad på den granskade informationen. För att kunna göra utförligare tester skapades 3D-utskrifter av varje utveckling. Resultatet blev en kanna som är utformad för att möjliggöra en enkel och ergonomisk användning. Den är även anpassad för effektiv och stabil förvaring i ATLAS-lådor, enkel påfyllning av dryck samt rengöring. Då kannan rymmer 1,5 liter ger det en perfekt kombination av antal serveringar, påfyllningar av kannan samt en låg vikt. Kannan är formsprutad och är tillverkad i den Bisfenol A-fria plasten Tritan. Greppet är utformat för att ge kannan en ergonomisk användning för olika stora händer och är symmetrisk för att möjliggöra lika användning av både höger- och vänsterhänta. Pipen ger en kontrollerad och jämn stråle samt en droppfri servering genom att skära av strålen ordentligt. Pipen är utformad så att kannan endast behöver vinklas 90 grader från upprätt läge för att kunna tömmas. Locket är en separat del som sätts på kannan med presspassning och hjälper till att kontrollera strålen under servering samt förhindra spill vid eventuell turbulens. Författarna anser att syftet har uppfyllts genom att en grundlig teoretisk referensram och en empirisk studie genom intervjuer och en fallstudie utfördes.

Thise thesis for 15 credits/student were executed at Zetterbergs Industry AB in Östervåla by two students. Zetterbergs develops, manufactures and mount bodywork and components for transporting trucks. Their main focus is earthmovers in the nordic countries. Recently Zetterbergs released a new dumper for hooklifts called ZD4-LV. The company promote it as a lightweight dumper for hooklifts with an appealing design. The dumper for hooklifts is built after the swedish standard and Zetterbergs now wants to produce a dumper for hooklifts that follows the german standard, DIN 30722. In the beginning of the thesis a thorough examination of the two standards SS 3021 and DIN 30722. The company wanted the new dumper for hooklifts to use the same basket as ZD4 so the student examined how the ZD4-LV was designedconstructed and manufactured. To generate concepts the five-step method were used. To figure out the best concept Pugh’s matrix were used. The result is a complete CAD-model with associated manufacturing drawings of a complete dumper for hooklifts that follows DIN 30722. New models and drawings have been made for all the new parts and assemblies, but for the existing parts, it uses the existing drawingsexisting drawings will be used. The thesis is considered a success hence all set goals were met. / Examensarbetet utfördes på Zetterbergs Industri AB i Östervåla. Arbetet är ett 15 högskolepoängsarbete/student dvs cirka 20 veckors arbete totalt då arbetet är utfört av två studenter. Zetterbergs konstruerardesignar, tillverkar och monterar lastbilspåbyggnader och har deras tyngdpunkt på anläggningsfordon i Norden. Zetterbergs släppte nyligen ett nytt lastväxlardumperflak kallat ZD4-LV. Detta flak marknadsförs som en lågviktare med snygg design. Flaket är byggt enligt svensk standard och Zetterbergs vill ta fram en variant på flaket som istället följer den tyska standardentysk standard som används i Europa.  Arbetet tog sin början i en granskning av de två olika standarderna SS 3021 och DIN 30722. Även den svenska varianten av ZD4-LV gicks igenom för att få en djupare förståelse i hur flaket var uppbyggt. Då det önskades att korgen från den befintliga lastväxlardumpern skulle används för den europeiska varianten så gjordes en granskning även i hur den befintliga lastväxlardumpern tillverkas. Femstegsmetoden användes för att generera olika koncept som sedan utvärderas och viktades i en Pugh matris. De valda koncepten från Pugh matriserna vidareutvecklades vidare som senare senare som mynnade ut i ett antal slutgiltiga konstruktioner. Resultatet blev en färdig CAD-modell med tillhörande tillverkningsritningar av en komplett lastväxlardumper som följer den europeiska tyska standarden DIN 30722. Ritningar och CAD-modeller har gjorts på samtliga delar och sammanställningar förutom på befintliga delar då dessa redan finns. Arbetet anses lyckat då alla uppsatta mål har blivit uppfyllda samt att en del extra önskemål har kunnat tillgodoses.

The interest in using finite element analysis (FEA) as a product development tool is present within IKEAof Sweden (IoS). To gain additional support from within IoS a project was issued to identify the meritsand demerits of FEA. This was done by applying FEA to optimise an existing product, namely theEktorp sofa frame. Three important questions are addressed in this report: • How can the finite element method efficiently and reliably be applied to improve an existingproduct? • What types of improvements can be anticipated from using the finite element method andhow can these be achieved? • What products are suitable to be developed with the use of FEA? As the sofa frame mainly consists of wood a literature study is conducted to answer several questionsregarding the use of wood in conjunction with FEA. Real life tests are performed to verify acquiredmaterial data. The original design is analysed with FEA to act as reference for newer concepts and also to identifyareas of improvement. Additional design tools are also applied to complement the FEA. Concepts are generated to improve a number of factors such as weight, number of components andcost. These concepts are analysed with FEA to be compared to the original design and incrementallychanged until meeting set requirements. A final concept where the cost, weight and number of components are reduced is thoroughlydescribed and presented as a CAD model. The final result is the Ektorp sofa frame with its weightreduced by 10.9%, number of components reduced by 18.2% and material cost reduced by 13.4%. The conclusion from this process is that FEA can efficiently and reliably be applied to improve anexisting product. This, however, requires thorough knowledge in FEA. Strength, weight and cost arethe most obvious factors that can benefit from the use of FEA while almost all design changes canbenefit indirectly as well. Almost any product can benefit from the use of FEA; however, severalfactors decide the efficiency and reliability of these analyses, such as analysis experience and productcomplexity. / Det finns ett intresse för att använda finita element analyser (FEA) som ett produktutvecklingsverktygpå IKEA of Sweden (IoS). För att få ett ökat stöd inom IoS skapades ett projekt där för och nackdelarnamed FEA kan identifieras. Detta projekt baserades på att optimera en existerande produkt, nämligenEktorp soffans ram. Tre viktiga frågor behandlas i och med detta projekt: • Hur kan finita element metoden appliceras på ett effektivt och tillförlitligt sätt för att optimeraen existerande produkt? • Vilka typer av förbättringar kan man förvänta sig genom att använda finita element metodenoch hur uppnås dessa? • Vilka produkter lämpar sig att utvecklas med hjälp av FEA? Eftersom soffans ram till större delen består av trä inleds en litteraturstudie för att besvara frågor somberör användandet av trä i samband med FEA. Verkliga tester utförs för att verifiera insamladematerialdata. Originalkonstruktionen analyseras med FEA för att skapa en referens till kommande koncept och ävenför att identifiera möjliga förbättringsområden. Flera designverktyg används för att komplettera FEA. Koncept genereras för att förbättra en rad faktorer såsom vikten, antalet komponenter och kostnaden.Dessa koncept analyseras med FEA och jämförs mot originalkonstruktionen för att förbättrasinkrementellt tills det att fastställda krav uppfylls. Ett slutgiltigt koncept där kostnad, vikt och antalet komponenter är minskat beskrivs i detalj ochpresenteras som en CAD modell. Det slutgiltiga resultatet är Ektorp-soffans ram där vikten ärreducerad med 10,9%, antalet komponenter reducerade med 18,2% och materialkostnadernareducerade med 13,4%. Slutsatsen från projektet är att FEA kan appliceras på ett effektivt och tillförlitligt sätt för att förbättraen existerande produkt. Detta kräver dock omfattande kunskap inom FEA. Hållfasthet, vikt ochkostnad är de mest uppenbara parametrar som kan tjäna på användandet av FEA medan nästan allakonstruktionsändringar kan dra nytta av FEA indirekt. Nästan alla produkter kan dra nytta av FEA, detfinns dock en rad faktorer som avgör hur pass effektiva och tillförlitliga analyserna blir. Exempel pådessa är användarerfarenhet och produktkomplexitet.