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ABSTRACT
The purpose of this project is to design and analysis of “Multi LED Machine Fixture” using CAD tools. This project is carried out to create a new machine fixture of cutting and bending simultaneously for the small electronic industry. This machine has a lot of advantages which the geometry design machine is not too big and the height is
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ABSTRAK
Projek ini bertujuan untuk merekacipta dan menganalisa sebuah mesin “Multi LED
Machine Fixture” dengan menggunakan perisian CAD. Projek ini dijalankan untuk
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DEDICATION
A million praise towards my parents, my respectful supervisor, examiner and lectures and to all my friends for their support and cooperation in helping me to complete the report.
Thanks to UTeM staff for their guidance and information given during my PSM. Their information helps me a lot in preparing the report.
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ACKNOWLEDGEMENT
Greatest praise to Allah Almighty. Grateful to Him with His will, I had successfully
finished in preparing this „Projek Sarjana Muda‟ thesis and completing my Bachelor‟s
degree in Manufacturing Engineering in Design at Universiti Teknikal Malaysia Melaka (UTeM).
I would like to express my sincerity appreciation to my supervisor, En. Taufik for the arrangement, an advice and assistance given for my PSM project.
I would like to take this opportunity to express my warmest and greatest appreciation for all the parties who had assisted me in making this PSM program a success one. My thanks go to Faculty of Manufacturing Engineering (FKP) management, library department and project PSM members for their willingness in giving me opportunity to undergo my PSM.
Last but not least, my thanks go to all friends that give much support during the completion this final year project report. This opportunity absolutely taken to wish special thank for several people especially mom and all the family members for supporting physically and spiritually throughout in completing this project.
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2.1.1 Fixtures Definition 6
2.1.2 Description of the Fixture 7
2.1.3 Element of Fixtures 9
2.1.4 Fixture Design 10
2.1.5 Fixture Design Criteria 12
2.2 Work Holding Devices 12
2.2.1 Definition 12
2.2.2 Typical Work Holding Devices 12
2.2.3 Principles of Work Holding 13
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2.3 Material Selection 16
2.3.1 Definition of Material Selection 16
2.3.2 Material Classification and Properties 16
2.3.3 Material Selection Process 18
2.3.4 Primary Manufacturing Methods 20
2.4 Human Factors 20
2.4.1 Definition of Human Factor 20
2.4.2 Human Behavior 21
2.4.3 Human Sensory Capabilities 22
2.4.4 Anthropometric Data 23
2.5 QFD Method 25
2.5.1 Definition of the QFD 25
2.5.2 QFD Process 25
2.5.3 Definition of the House of Quality (HoQ) 26
2.5.4 Steps of HoQ 27
2.5.5 The Benefits of Using the QFD 29
2.5.6 The setbacks of using QFD 30
2.6 Concept Scoring 30
2.6.1 Definition of the Concept Scoring 30
2.6.2 Steps of Concept Scoring 31
2.7 Computer Aided Design (CAD) 36
2.7.1 Solidworks 37
2.8 Computer Aided Engineering (CAE) 39
2.8.1 COCMOSXpress 40 2.10.1 Definition of Multi LED Machine Fixture 45
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4. RESULTS & ANALYSIS 54
4.1 Method Apply 55
4.1.1 Quality Function Deployment (QFD) 56
4.1.2 Concept Scoring 57
4.2 The Engineering Sketch 57
4.2.1 Concept Design 1 58
4.2.2 Concept Design 2 59
4.2.3 Concept Design 3 60
4.3 Design Selection 61
4.3.1 Design Requirement of Multi LED Machine Fixture 61
4.4 Detail Drawing Stage 63
4.4.1 Detail Drawing of Multi LED Machine Fixture 64 4.5 Photo Gallery of The Multi LED Machine Fixture 66
4.6 Bill of Material 69
4.6.1 Product Tree Structure 70
4.6.2 Function of Each Component 71
4.7 Machine Used and Process Involved 72
4.7.1 Rapid Prototype Machine 73
4.7.2 Tool and Cutter Grinder 85
4.8 Operation Flow Chart 89
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4.8.2 Fabrication, Assembly and Verification Stage 90
4.9 COSMOSXpress Analysis 91
4.9.1 Stress and Deformation Analysis 91
4.9.1.1 Cover (Male) 92
4.9.1.2 Base (Female) 97
4.9.1.3 Cutter 102
4.10 ANSYS Simulation 107
4.10.1 Model 108
4.10.1.1 Mesh 108
4.10.2 Environment 108
4.10.2.1 Structural Loading 109
4.10.2.2 Structural Supports 109
4.10.3 Solution 109
4.10.3.1 Structural Results 110
4.10.3.2 Equivalent Stress Safety 110
4.10.3.3 Shear Stress Safety 111
4.10.4 Appendices 112
4.10.4.1 Definition of Structural Steel 112
5. DISCUSSION 113
5.1 The Product – Multi LED Machine Fixture 113
5.2 Operation Cycle Time Analysis 114
5.3 Material Characteristic 115
5.4 Problems while Completing Task 115
5.5 COSMOSXpress Analysis 116
5.5.1 Cover (Male) 117
5.5.2 Base (Female) 117
5.5.3 Cutter 118
5.6 ANSYS Simulation 119
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REFERENCES 125
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LIST OF TABLES
2.1 Material Properties 19
2.2 Human Color Vision 22
2.3 The concept scoring matrix. 31
2.4 Concept Rating 33
3.1 Gantt chart for PSM 1 52
3.2 Gantt chart for PSM 2 53
4.1 Mission Statement of Multi LED Machine Fixture 55
4.2 Result of Concept Scoring 57
4.3 Function of each components 71
4.4 Estimated Build Time Table 84
4.5 Materials for Cover 92
4.6 Restraint Information for Cover 92
4.7 Load Information for Cover. 93
4.8 Mesh Information for Cover 93
4.9 Solver Information for Cover 93
4.10 Stress Results for Cover 94
4.11 Displacement Results for Cover 94
4.12 Deformation Results for Cover 95
4.13 Appendix for Cover 96
4.19 Solver Information for Base 98
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4.21 Displacement Results for Base 99
4.22 Deformation Results for Base 100
4.23 Appendix for Base 101
4.24 Base Property 101
4.25 Materials for Cutter 102
4.26 Restraint for Cutter 102
4.27 Loads for Cutter 103
4.28 Mesh Information for Cutter 103
4.29 Solver Information for Cutter 103
4.30 Stress Results for Cutter 104
4.31 Displacement Results for Cutter 104
4.32 Deformation Results 105
4.33 Appendix for Cutter 106
4.34 Cutter Property 107
4.35 Bodies 108
4.36 Structural Loads 109
4.37 Structural Supports 109
4.38 Values 110
4.39 Definition 110
4.40
Results
1114.41
Definition
1114.42
Results
1114.43 "Structural Steel" Constant Properties. 112
5.1 Alternating Stress 120
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LIST OF FIGURES
2.1 Plate Fixture 8
2.2 Angle-plate fixture 9
2.3 Modified angle-plate fixture 9
2.4 Various aspect of fixture design 11
2.5 Elementary Work Holder 13
2.6 Vise with hydraulic clamping 13
2.7 Locating and clamping principles 14
2.8 The twelve degrees of freedom 14
2.9 Human-Machine System 21
2.10 Standing adult man 24
2.11 Quality function deployment process 25
2.12 House of Quality 26
2.13 House of Quality Matrix 27
2.14 Hierarchical decomposition of selection criteria 32
2.15 SolidWorks Hierarchy 38
2.16 Nonlinear statistics analysis of a 3D structure subjected to plastic deformations with Code-Aster
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2.17 Static Stress Analysis 41
2.18 ANASYS Analysis 42
2.19 Rapid Prototype Machine 42
2.20 Tool and Cutter Grinder 44
2.21 Front view and side view of the LED Bending machine fixture 45
3.1 Flow Chart for PSM 1 48
3.2 Flow Chart for PSM 2 50
4.1 House of Quality for Multi LED Machine Fixture 56
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4.3 Concept design 2 59
4.4 Concept design 3 60
4.5 Isometric Drawing of Multi LED Machine Fixture 64 4.6 Front view and the side view of the multi LED machine fixture 64 4.7 Concept design 2 of the multi LED machine fixture (Assembly view) 65
4.8 Multi LED Machine Fixture. 66
4.9 Load the LEDs into the slot provided 67
4.10 Bending and Cutting Process 67
4.11 LED Waste 68
4.12 Product Results 68
4.13 Bill of material for multi LED machine fixture 69 4.14 Product tree structure for multi LED machine fixture 70
4.15 Turn „ON‟ the machine 73
4.16 Loading the canister 74
4.17 Peel the foil tape 74
4.18 Remove the plastic cap 75
4.19 Handling Instruction 75
4.20 Feed the filament 76
4.21 Remove the square foam gasket 76
4.22 Stick the gasket onto the canister 77
4.23 Save file to STL (*.stl) 77
4.29 Create Support Button 80
4.30 Creating Support 81
4.31 Toolpath Button 81
4.32 Create Toolpath for the part. 82
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4.34 Flag Button 83
4.35 Flag Shortcut Procedure 83
4.36 Rapid Processes 84
4.44 Operation flow chart for multi LED machine fixture 89
4.45 Design Safety for Cover 92
4.46 Stress Results for Cover 94
4.47 Displacement Results for Cover 95
4.48 Deformation Results for Cover 95
4.49 Design Check Results for Cover 96
4.50 Design Safety for Base 97
4.51 Stress Analysis Result for Base 99
4.52 Displacement Analysis Result for Base 100
4.53 Deformation Result for Base 100
4.54 Base Results. 103
4.55 Design Safety for Cutter 102
4.56 Stress Results for Cutter 104
4.57 Displacement Results for Cutter 105
4.58 Deformation Results for Cutter 105
4.59 Cutter Results 106
4.60 Element Solution 107
5.1 Failure Analysis 116
5.2 Cutter Areas 118
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5.4 Alternating Stress. 120
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LIST OF ABBREVIATIONS
$ - Dollar
3D - Three-Dimensional
a - Lever Length
AG - Aktiengesellschaft (German Words: Domain) BMW - Bayerische Motoren Werke
C++ - C Plus Plus
CA - Customer Attributes CAD - Computer Aided Design CAE - Computer Aided Engineering CAM - Computer Aided Manufacturing
CATIA - Computer Aided Three Dimensional Interactive Application CAx - Computer Aided Technologies
CFD - Counterfactual Definiteness CNC - Computerized Numerical Control
dB - Decibel
DELMIA - Digital Enterprise Lean Manufacturing Interactive Application
Dr. - Doctor
E.g. - Example
En. - Encik (Sir)
etc - "and other things" or "and so on"
F - Human Force
FKP - Fakulti Kejuruteraan Pembuatan HoQ - House of Quality
i.e. - Example
IBM - International Business Machines
in - Inch
kg - Kilogram
xvii LED - Light Emitting Diode MEC - Milwaukee Electronics
mm - millimeter PLM - Product Lifecycle Management PSA - Professional Sports Authenticator PSM - Projek Sarjana Muda
QFD - Quality Function Deployment R&D - Research and Development RFID - Radio Frequency Identification
rij - Raw Rating of Concept j for The ith Criterion
RM - Ringgit Malaysia
SDRC -
Structural Dynamics Research Corporation
sec - Second
Sj - Total Score for Concept j
STL - Standard Template Library
T - Torque
TFT-LCD - Thin Film Transistor Liquid Crystal Display TR - Technical Requirements
UTeM - Universiti Teknikal Malaysia Melaka
v - Poisson‟s Ratio
V - Version
VOC - Voice of Customer
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CHAPTER 1
INTRODUCTION
This report described a project on improving multi LED fixture machine in electronic industry. This chapter explained on the background of project, problem statement, objectives, scope and report outline.
1.1 Background of Project
Electronics is the study of the flow of charge through various materials and devices such as semiconductors, resistors, inductors, capacitors, nano-structures and vacuum tubes. Although considered to be a theoretical branch of physics, the design and construction of electronic circuits to solve practical problems is an essential technique in the fields of electronic engineering and computer engineering. This science starts about 1908 with the invention by Dr Lee De Forest of the valve (triode) Before 1950 this science was named "Radio" or "Radio techniques" because that was its principal application. The study of new semiconductor devices and surrounding technology is sometimes considered a branch of physics.
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production to include more sophisticated high-end products such as silicon ingots, polishing silicon wafers, RFID, chip design, digital video disc players, electronic games, multimedia products and high resolution TFT-LCD and LED plasma displays.
LED means “Light Emitting Diode” which has been used a lot in electronic industry.
A strip light emitter comprises an LED light-emitting strip composed of a plurality of LEDs connected continuously in parallel between two conductors that make up negative (-) and positive (+) electrodes and are disposed roughly parallel to each other, and strip-shaped synthetic resin that is wider that the LED light-emitting strip and covers the LED light-emitting strip.
The function of LED as a lamp which can give a signal or warning and not been used to lighting among area. The LED light-emitting strip can be configured to emit light from both sides, be covered by a synthetic resin made from strip-shaped transparent vinyl with half-turn twists, be configured to be flexible by bringing the conductors close together, be provided with reflective sheets, be configured as a triangular marker, and be configured a buoyant marker for sea rescue having air pockets.
A fixture is a work holding device, which on the holds and positions the workplace, but does not itself guide locate or positions the cutting tool (Chapman and Martin, 2006). A fixture is a device for locating, holding and supporting a work piece during a manufacturing operation. Fixtures are essential elements of production processes as they are required in most of the automated manufacturing, inspection, and assembly operations. A fixture is production tool that locates, hold, and supports the work securely so the required machining operations can be performed (Hoffman, 2004). Fixtures hold the workpiece securely in the correct position with respect to the machine/cutter during operation(Joshi, 2003).
Multi LED Machine Fixture is one of the projects that used to solve the problem in cut and bend the LED in the same time. This machine is not only having a variety
function but it‟s also saved a production time and can do the cutting process in good
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automatically. Besides that it also safety guarantee and can produce a good quality product.
On the previous method, the project only used a single LED machine fixture. Means
that it‟s only can produce one LED in one time. As a result this single LED machine fixture increase a labor cost compared to this new design; multi LED machine fixture which is yield a higher production rate and can give a better performance.
1.2 Problem Statement
Based on the study and analysis shows that LED cut and bend machine only produce one LED in one time. The problem from the previous application is waste the production time and increase the labor cost. The other problem is the operation can‟t perform well because of LED conductors too small and nearest to each other and make it difficult to uniform cut.
With this “Multi LED Machine Fixture”, several ideas and design has been
conscientious to improve the fixture application. The fixture design is based on the safety environment and safety to use.
