Modeling for design simplification and power-flow efficiency improvement in an automotive planetary gearbox: A case example

Tamada, Sireesha; Chandra, Manish; Patra, Prasenjit; Mandol, Sourabh; Bhattacharjee, Debraj; Dan, Pranab K.

doi:10.5937/fme2003707t

Cited by 6 publications

(4 citation statements)

References 35 publications

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“…Because the product had already been produced, and this work essentially aimed to develop new methodologies capable of improving the processes through proper integration, it was considered feasible to adopt the design science research (DSR) methodology. In fact, this methodology was developed essentially to allow improvements to be introduced in processes or to develop new products from existing ones, and it can also be applied in other types of situations [54][55][56][57][58]. Regarding the DSR methodology, Teixeira et al [59] state that it is particularly useful due to its "technological background and its focus on developing models and methods that address complex and ill-defined problems".…”

Section: Methodology Followedmentioning

confidence: 99%

A Novel Fully Automatic Concept to Produce First Subset of Bowden Cables, Improving Productivity, Flexibility, and Safety

Eiras,

Silva,

Campilho

et al. 2023

Machines

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With a view to maintaining the competitiveness required by the market, the automotive industry strongly encourages its suppliers to develop new production methods and technologies capable of reducing the costs of produced products, ensuring the necessary quality, and increasing flexibility, with a view to responding more easily to the customization of the products that the market increasingly demands. The main goal of this work was to increase the flexibility and productivity of equipment capable of producing the first subset that constitutes the product commonly known as the Bowden cable. To this end, the design science research methodology was used, which was understood as the most effective in describing scientific work related to the improvement of existing systems. Bowden cables are cables that activate various devices in the car, such as opening doors, moving window glasses, and adjusting some car seats, among others. The work consisted of integrating several operations usually carried out for the manufacture of the referred subset, reducing logistics operations and manual work, increasing operator safety, and increasing the production rate and flexibility of the equipment, by reducing the setup time. For this purpose, new mechanical concepts were developed, and automation was applied, which resulted in a completely new concept, able to fulfill all the objectives initially set. It should be noted here that the new equipment allowed a production rate of 1140 p/h, when the initial objective was 1100 p/h; it requires an investment of only around EUR 55,000 (easy return on investment), occupies only 11.6 m2, and has reinforced safety systems to avoid workers’ injuries, an aspect that is very important in this type of equipment, where operators deal with cutting systems and high temperatures. The dissemination of this concept could help other researchers to easily find solutions to certain problems that they face in the development of modern equipment. The main contributions of this paper are the novel concepts created to overcome some process difficulties, which can be used for a wide range of other processing situations with similar difficulties. The solutions proposed allow a decrease in the cycle time, present high flexibility, save workshop space, and are affordable in terms of global cost.

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Section: Methodology Followedmentioning

confidence: 99%

A Novel Fully Automatic Concept to Produce First Subset of Bowden Cables, Improving Productivity, Flexibility, and Safety

Eiras,

Silva,

Campilho

et al. 2023

Machines

View full text Add to dashboard Cite

show abstract

“…The DSR methodology was adopted in the development of this work, based on published works of authors such as Vaishnavi and Kuechler [44]. This methodology is usually adopted when developing new concepts from existing ones [45,46]. Since, in this work, the presented concept was developed based on an existing Bowden cable production process, this methodology was adopted.…”

Section: Methodsmentioning

confidence: 99%

“…In the present work, a newly developed fully automated Bowden cable production process is presented that is able to produce three different cable types and twenty-four different cable references (having different dimensions). For the development of this novel concept, the design science research (DSR) methodology was employed, which comprises of six stages: (1) problem identification, (2) definition of objectives for a solution, (3) design and solution development, (4) demonstration of the solution, (5) evaluation of the proposed solution, and (6) drawing conclusions [44][45][46]. This work shows that the correct study of a problem and the clever implementation of automation in a production process enable an increase in production and a reduction in cycle time, without the need for more expensive implementations, such as the use of robotics.…”

Section: Introductionmentioning

confidence: 99%

Developing a Novel Fully Automated Concept to Produce Bowden Cables for the Automotive Industry

et al. 2022

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The automotive industry is one of the driving forces of the global industry; thus, it is a very competitive sector which creates a constant need for process improvement, regarding productivity, quality, and flexibility. Automation has proven to be a viable solution for these production problems, with the rising adoption of these automated system by companies that try to design and implement more flexible systems, while reducing costs and improving process quality. Furthermore, the use of automation reduces the manpower factor and its associated variability. In the present work, a new concept for a Bowden cable production process is presented by employing the design science research (DSR) methodology. The project starts with the analysis of the previous production concept, determining possible problems and improvements, as well as setting objectives/requirements for a possible new concept/equipment. This information was used to develop a new automated Bowden cable production equipment, implementing several changes to the old concept and filling a gap in the literature in this field. The developed system was implemented and tested. A considerable reduction in cycle time was registered by 25%, which resulted in an increase of 30% in process productivity.

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“…The design science research (DSR) is a usually used methodology to develop new products from existing ones, among others [26][27]. Grenha et al [28] refer DRS as a convenient methodology due to its "technology background and its focus on developing models and methods that address complex and ill-defined problems".…”

Section: Introductionmentioning

confidence: 99%

Case-based product development of a high-pressure die casting injection subset using design science research

Tojal¹,

Silva²,

Campilho³

et al. 2022

FME Transactions

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High pressure die casting is widely used in metalworking industry. Many of the components and devices directly linked to the hot parts are subjected to severe wear. However, some design updates can enlarge the lifespan of these components and devices. This paper proposes to show how a sustainable maintenance can be obtained by focusing resources on the analysis of the critical problem and its consequent mitigation, whereas they are originated on the human, machine/process or supplier level. Design science research (DSR) was the iterative research methodology chosen to integrate this work. The completion of the objective with the implementation of this new injection subset concept brought extremely beneficial results, such as reduction of its consumption, reduction of acquisition cost and waste generated, and reduction of the intervention time during maintenance operations, as well as increase in equipment availability time.

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Modeling for design simplification and power-flow efficiency improvement in an automotive planetary gearbox: A case example

Cited by 6 publications

References 35 publications

A Novel Fully Automatic Concept to Produce First Subset of Bowden Cables, Improving Productivity, Flexibility, and Safety

A Novel Fully Automatic Concept to Produce First Subset of Bowden Cables, Improving Productivity, Flexibility, and Safety

Developing a Novel Fully Automated Concept to Produce Bowden Cables for the Automotive Industry

Case-based product development of a high-pressure die casting injection subset using design science research

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