Automating The Production Of The Automotive Retainer Using The Rotary Indexing Mechanism.
ABSTRAK
Pengeluaran semasa untuk penahan automotif dalam industri adalah melalui kaedah
proses konvensional. Proses ini melibatkan penggunaan operasi manual bagi mesin
penekanan besar dan jig. Pendekatan ini memerlukan penglibatan yang tinggi
daripada pekerja di bahagian pengeluaran. Akibatnya, masa kitaran yang diperlukan
lebih panjang untuk melengkapkan proses tersebut. Keadaan ini secara tidak
langsung akan mengurangkan kadar pengeluaran. Operasi manual dalam pendekatan
ini juga menyebabkan kos buruh yang lebih tinggi. Bagi mengatasi isu-isu ini,
mengautomasikan pengeluaran penahan automotif dilihat sebagai satu pendekatan
yang berpotensi. Idea utama projek ini adalah mencadangkan satu konsep reka
bentuk sistem automasi untuk pengeluaran penahan automotif. Konsep ini
mencadangkan penggunaan mekanisme pengindeksan berputar. Tiga peringkat akan
terlibat dalam projek ini. Pertama, ia melibatkan kajian tentang sistem pengeluaran
yang berkaitan. Kajian ini adalah untuk mendapatkan maklumat yang berasas tentang
jenis penahan automotif, pengeluaran penahan automotif di dalam tangki bahan api,
pendekatan pemindahan bahan dalam sistem pengeluaran, peralatan dalam reka
bentuk sistem pembuatan serta analisis mekanisme pengindeksan putar untuk sistem
pengeluaran automatik. Peringkat kedua ialah peringkat reka bentuk. Reka bentuk
dan simulasi proses sistem automatik yang dibangunkan akan melibatkan
penggunaan perisian CATIA. Peringkat akhir melibatkan dengan simulasi dan
analisis hasil simulasi. Apabila sistem pengeluaran automatik telah direka, proses
analisis akan dilakukan dengan menggunakan perisian SolidWorks. Analisis ini akan
melibatkan perbandingan menyeluruh pada masa kitaran semasa dan kadar
pengeluaran dengan versi automasi yang dicadangkan. Keputusan dijangka akan
meningkatkan kitaran masa dan juga kadar pengeluaran. Apabila semua siap,
pendekatan sistem pengeluaran automatik dalam menghasilkan penahan automotif
diharap dapat memberi manfaat kepada industri.
i
ABSTRACT
The current production of automotive retainer in the industry is through conventional
process. The process involves the use of manual operation of huge stamping
machines and its jigs. This approach requires high involvement of workers in the
production line. As a consequence, longer cycle time is required to complete the
process. This situation will indirectly lower the production rate. The manual
operation in this approach also indicates higher labour cost. To overcome these
issues, automating the production of automotive retainer is seen as a potential
approach. The main idea of this project is to propose a design concept of automation
system for the production of the automotive retainer. The propose concept include
the utilization of rotary indexing mechanism. Three stages were involved in this
project. Firstly, it involves the study of the related production systems. The study
involving reviews on the related production system has been included in this project.
The review is to gain the information based on the type of automotive retainer, the
production of the automotive retainer in fuel tank, material transfer approach in the
production system, tools in design of manufacturing system as well as analysis of the
rotary indexing mechanism for automated production systems. The second stage is
the design stage. The design and simulation process of the developed automated
system involved the use of CATIA software. The final stage involves with the
simulation and analysis of the simulation outcomes. Once the automated production
system has been designed, the analysis process is performed using SolidWorks
software. This analysis include a thorough comparison on the current cycle time and
production rate with the proposed automation version. The results show the
improvement of the cycle time as well as the production rate. The outcome of this
new automated approach in producing the automotive retainer is hoped to benefit the
industry in the future.
ii
DEDICATION
To my beloved parents Abd Rashid Jubari and Hasnah Mohd Amin, my supportive
siblings and my fellow friends,I love u all.
iii
AKNOWLEDGEMENT
Bismillahirrahmanirrahim. With the name of Allah the most Gracious and the most
Merciful.
First of all, I would like to thank Allah for giving me the strength to get this paper
done. I would like to express my utmost appreciation to Dr. Muhamad Arfauz bin A
Rahman who is my final year project supervisor. The supervision and support that he
gave truly help the progression and smoothness of completing this project. Not to
mention that all my friends those have been helping me in completing this research
and my beloved parents that gives all their support in completing my project.
iv
TABLE OF CONTENTS
Abstrak
i
Abstract
ii
Dedication
iii
Aknowledgement
iv
Table of Content
v
List of Tables
viii
List of Figures
ix
List Abbreviations, Symbols and Nomenclatures
xii
CHAPTER 1 : INTRODUCTION
1
1.1
Background
1
1.2
Problem statement
3
1.3
Objectives of Project
4
1.4
Scopes and Limitations of Project
4
1.5
Structure of the Report
5
CHAPTER 2 : LITERATURE REVIEW
6
2.1
Retainer
6
2.1.1
Automotive retainer
7
2.1.1.1 Automotive retainer at fuel tank
7
2.1.1.2 Automotive retainer at pipe filter oil
8
2.1.1.3 Automotive retainer at body car
9
2.1.2 Retainer in other application
2.2
9
Production of the automotive retainer in fuel tank
10
2.2.1
Stamping process
11
2.2.2
Tapping process
12
2.2.3
Assembly process
13
2.2.4
Manual production process
14
v
Automated production process
14
Material transfer in production system
15
2.3.1
Rotary indexing mechanism
15
2.3.2
In-line transfer
17
2.3.3
Robot
18
2.2.5
2.3
2.4
2.5
Tools in design and analysis of manufacturing process
19
2.4.1
CATIA software
19
2.4.2
SolidWorks software
20
2.4.3
Arena software
21
Analysis of the rotary indexing mechanism for automated production
22
process
2.6
2.5.1
Cycle time
22
2.5.2
Production rate
23
Concluding remarks
24
CHAPTER 3 : METHODOLOGY
25
3.1
Introduction
25
3.2
Project flowchart and gantt chart
25
3.3
Review of the current production process
27
3.4
Study and analysis the current production process
28
3.5
Determination the suiTable automated production process
29
3.5.1
Flow process in automated system
31
3.5.2
Flow process for mold during automated process approached
34
3.6
Design of the automated production process
36
3.7
Simulation of automated production propose using SolidWorks
37
3.7.1
38
3.8
3.9
Motion simulation of automated process
3.7.2
User interface in motion simulation
40
3.7.3
Analysis of motion simulation
41
Analysis of the automated production process
42
3.8.1
Determination of cycle time
42
3.8.2
Computation of production rate
42
Summary of chapter 3
42
vi
CHAPTER 4 : RESULT, ANALYSIS AND DISCUSSION
43
4.1
Engineering design
43
4.1.1
Part design
43
4.1.2
Assembly design
56
4.1.2.1 Complete assembly design of the stamping
machine
56
4.1.2.2 Complete assembly design of the automatic stamping
machine
57
4.1.2.3 Complete assembly design of the rotary
table
58
4.1.2.4 Complete assembly design of the magazine
table
59
4.1.2.5 Complete assembly design of the mold
section 1
59
4.1.2.6 Complete assembly design of the mold section
2
60
4.1.2.7 Complete assembly design of the mold section
60
3
4.1.2.8 Complete assembly design of the plant layout for automation
production line
4.2
4.3
61
Cycle time
62
4.2.1
Conventional process
62
4.2.2
Automated process
67
Analysis
70
CHAPTER 5 : CONCLUSION AND RECOMMENDATION
74
5.1
Conclusion
74
5.2
Recommendation for future research
75
REFERENCES
76
APPENDICES
79
vii
LIST OF TABLES
3.1 The shortcut button in motion tool bar.
41
4.1 Individual parts of the stamping machine.
44
4.2 Individual parts of the Automatic tapping machine.
45
4.3 Individual parts of the Automatic tapping machine. (continued)
46
4.4 Individual parts of the rotary table.
47
4.5 Individual parts of the rotary table. (continued)
48
4.6 Individual parts of the rotary table. (continued)
49
4.7 Individual parts of the magazine table.
50
4.8 Individual parts of the magazine table. (continued)
51
4.9 Individual parts of the mold section 1.
52
4.10 Individual parts of the mold section 1. (continued)
53
4.11 Individual parts of mold section 2.
54
4.12 Individual parts of mold section 3.
55
4.13 Cycle time of conventional process for automotive retainer
63
4.14 Cycle time of conventional process for automotive retainer
64
4.15 Cycle time of conventional process for automotive retainer
65
4.16 Average of cycle time for Conventional process.
66
4.17 Cycle time of automated process for automotive retainer
67
4.18 Average of cycle time for automated process approached.
70
4.19 Total cycle time of the production process.
70
4.20 Production rate of types production process.
71
viii
LIST OF FIGURES
1.1 Complete part of Automotive retainer (Sourse : United
1
1.2 Fuel tank upper that assembled with automotive retainer. (Source : United
Vehicles Industries Sdn. Bhd.)
2
2.1 A perspective view of automotive oil pump fixing ring. ("Automotive oil pump
fixing ring," 2013)
2.2 Aperspective view of fuel tank filler pipe retainer. (Craig & Cupp, 1983)
7
8
2.3 The detail design and application of retainer ball bearing. (Principle
Engineering)
10
2.4 The detail process and shaped for stamping process. (Dalessandro, Lorenz, &
Carr, 1998)
12
2.5 The view of threading fitting. (Groh, 1965)
13
2.6 The geneva mechanism. (Choubey & Rao, 1983)
16
2.7 The perspective view of an improved cross bar transfer press. (Bruns, 1993) 17
2.8 Robotic press machine. (Vieth R, 1999)
18
2.9 The icon of the CATIA Software. (Source : Internet)
19
2.10 Optimal part-programming in industry. (Source :
http://www.flowwaterjet.com/en.aspx)
20
2.11 The Arenasoftware. (Source : Internet)
21
3.1 Project flowchart
26
3.2 Stamping process cycle time study. (Source : United Vehicles Industries Sdn.
Bhd.)
28
3.3 Stamping process cycle time study. (Source : United Vehicles Industries Sdn.
Bhd.)
29
3.4 Rotary indexing mechanism. (Groover, 2008)
30
3.5 The proposed design layout.
31
3.6 The raw material.
32
3.7 Blanking process.
32
3.8 Chemfering process.
32
3.9 Pierching process.
33
3.10 Form/Embossing process
33
ix
3.11 Tapping process.
33
3.12 Process flow for the stamping machine at section 1.
34
3.13 Process flow for stamping machine at section 2.
35
3.14 Process flow for tapping machine at section 3.
35
3.15 The list of types for selection window.
36
3.16 The file selection.
37
3.17 The assembly workbench window.
37
3.18 Ground part for the floor of automated system approached.
39
3.19 Moving part for sub assembly in automated system approached.
39
3.20 Motion manager in the SolidWorks.
40
3.21 Time line area for motion analysis.
41
4.1 3D view of body stamping machine.
44
4.2 3D view of shaft stamping.
44
4.3 3D view of platform.
44
4.4 3D view of table.
45
4.5 3D view of motor.
45
4.6 3D view of shaft stamping machine.
45
4.7 3D view of spindle head.
46
4.8 3D view of tapper.
46
4.9 3D view of platform.
46
4.10 3D view of table.
47
4.11 3D view of rotary platform.
47
4.12 3D view of bracket cylinder.
47
4.13 3D view of big cylinder.
48
4.14 3D view of small cylinder.
48
4.15 3D view of long shaft.
48
4.16 3D view of short shaft.
49
4.17 3D view of small bracket.
49
4.18 3D view of end tool gripper.
49
4.19 3D view of table.
50
4.20 3D view of feed track.
50
4.21 3D view of bracket.
50
4.22 3D view of cylinder actuator.
51
x
4.23 3D view of shaft.
51
4.24 3D view of repellent.
51
4.25 3D view of bottom mold.
52
4.26 3D view of bottom die.
52
4.27 3D view of top mold.
52
4.28 3D view of big stripper.
53
4.29 3D view of small stripper.
53
4.30 3D view of bottom mold.
54
4.31 3D view of die.
54
4.32 3D view of top mold.
54
4.33 3D view of bottom mold.
55
4.34 3D view of jig.
55
4.35 Isometric view of the stamping machine assembly.
56
4.36 Isometric view of the automatic tapping machine.
57
4.37 Isometric view of the rotary Table.
58
4.38 Isometric view of the magazine Table.
59
4.39 Isometric view of the mold section 1.
59
4.40 Isometric view of the mold section 2.
60
4.41 Isometric view of the mold section 3.
60
4.42 Schematic view of the plant layout.
61
4.43 Bar graph for the production rate of different process approached.
72
xi
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
CATIA
-
Computer aided three-dimensional interactive application
AMS
-
Automated manufacturing system
CAD
-
Computer aided drawing
ICG
-
Interactive computer graphics
3D
-
Three dimensional
CAM
-
Computer aided manufacturing
CAE
-
Computer aided engineering
FMS
-
Flexible manufacturing system
DOF
-
Degree of freedom
IGS
-
Initial Graphic Specifications
xii
1 CHAPTER 1
INTRODUCTION
1.1 Background
In manufacturing the automotive fuel tank, there are few child parts required and
used to complete the construction of one fuel tank. The child parts that are assembled
in the fuel tank includes the tube breather, pipe fuel inlet, plate Fuel Tank separating,
sub-part tank fuel, Support Fuel sub-tank, Reinforcement fuel tank upper and clamp.
One of the prominent and important child parts is the bracket. The bracket is known
as an automotive retainer that uses to attach the fuel pump assembly. The automotive
retainer is assembled at the upper fuel tank at the lid of the fuel pump assembly.
Figure 1.1 and Figure 1.2 below show the automotive retainer in the fuel tank.
Figure 1.1 : Complete part of Automotive retainer (Sourse : United
Vehicles Industries Sdn. Bhd.)
1
Small
diameter size
for retainer
Big diameter
size for
retainer
Figure 1.2: Fuel tank upper that assembled with automotive retainer.
(Source : United Vehicles Industries Sdn. Bhd.)
From the Figure 1.2, the dimension sizes of the automotive retainer is divided into
two sizes. The big size dimension is attached at the center of fuel tank while the
smaller size is at the edge of the fuel tank. The function is same as a bracket which
is to attach the pump oil fuel and the tube of pump oil fuel.
In order to produce the parts of the fuel tank, the appropriate process manufacturing,
material selection and manufacturing system approach is concerned to get a better
fuel tank in case for the quality of the product. This is because the automotive fuel
tank is the safety product used by users. The production of the fuel tank needs to be
of high quality manufacturing process involving the child part, system production
and quality inspection. The material used to produce the fuel tank is made of sheet
metal. This sheet metal is shaped using stamping machine.
2
The production rate of automotive retainer is important to make sure the part is not
released before the assembly process occurs. The production rate of these parts must
be consistent that will be effect the process cycles time, the manufacturing stamping
process and the raw material. The process stamping that involved in the several types
such as the blanking process, chamfering process, form/embossing process, sheaving
process, piercing process, flattening process and tapping process.
In this industry, the current production process of automotive retainer is using the big
stamping machine and the conventional tooling. For examples, the process used the
stamping machine is also used for producing the retainer and other process to achieve
the desired parts. In addition, the mold and die can have changed to produce the other
parts as well as follow the company production planning. The operation of the
stamping machine needs at least one or two operators to operate the stamping
machine which includes the material input and output. After the stamping process
finished, the next process will be followed.
1.2 Problem statement
At present, the current production line approach used in the industry for the
production of the automotive retainer is through the conventional process. Typically
in the conventional process of an automotive retainer, stamping machine is widely
used. This is because of the large size of the stamping machine that is able to produce
this part. Hence, this will change the process method of stamping machine for
another process part. In brief, the problems identified due to the conventional
production line are as follows:
(a)
Longer cycle time to complete the process.
(b)
Lower production rate.
(c)
Higher labor cost increase to operate the production.
3
To overcome the elaborated issues, automated production system is seen as a
potential replacement system. The company can improve the production rate of the
automotive retainer through the design of the automated production line and reduce
the cycle time of the process.
1.3 Objectives of Project
To complete this project, three objectives have been identified. The objectives of this
project are:
(a)
To review and analyze the current production approach of the automotive
retainer in industry.
(b)
To propose the design conceptual of automating the production of the
automotive retainer using rotary indexing mechanism.
(c)
To analyze the cycles time and production rate for the proposed automated
production approach.
1.4 Scopes and Limitations of Project
The main idea of this project is to automate the production of the automotive
retainer. The proposed mechanism for this project will utilize the rotary indexing
mechanism. In this project, CATIA software and SolidWorks software will be used
to design the propose automated production line. Once the production line has been
designed, analysis of the cycle time will be analysed for the process involving both
the current method and the automated method will be performed.
Due to time constraint and the limitation of the software, this project does not
encompass on the design of the jig and fixtures for the handling of the retainer parts.
For the purpose of this project, the cycle time is calculated based on the material
handling of the input until end of the production line process.
4
1.5 Structure of the Report
The report is organized into five chapters. Chapter 1 will introduces the project
which includes background of project, problem statement, objectives to be achieved
throughout the project, scopes, as well as the limitation of the project.
Chapter 2, literature review begins by discussing several terms related to automated
production of the automotive parts, especially for retainer fuel tank, which is
followed by the system types of automated production that suiTable for the process
involved and the types of the material transfer mechanism on available design.
Chapter 3, methodology chapter discusses the method employed upon completing the
project. Mixed methodologies comprising qualitative and quantitative approached are
used to gather data. Flowcharts also will be shown for this chapter. Project design
and analysis are elaborate more to get the outcomes of the design of the production.
The simulation the automated production process will be created and analysed to get
the quantitative data such as the standard cycle time.
Chapter 4 is about the result, analysis and discussion with will discuss the outcomes
of the design and analysis of the automated production line, process selection to be
automated for appropriate process, engineering concept for manufacturing
production and the quantitative data of the cycle time process.
Chapter 5, the conclusion and recommendation chapter state the findings of the study
and discusses its implications. This study draws its conclusion primarily for the
design of automated production line as well as the analysis the time cycle process for
thisproject.
5
2 CHAPTER 2
LITERATURE REVIEW
This chapter summarizes the current state of knowledge and information about the
automating production of the automotive retainer using the rotary indexing
mechanism. The most important part of this chapter is the review of several scope of
the automotive retainer. Related issues regarding the production process system
includes the comparison between the automated process and the conventional
process. The review of cycle time and production rate of the production is also being
discussed. The basic idea of the material transfer in production process system is also
included. At the end of this chapter, there will be brief information of the design and
simulation of the automated process production which is created by using either
CATIA or SolidWorks software is included in this chapter.
2.1 Retainer
The retainer is defined as “a clip, frame or similar device that prevents a part of a
machine, engine and other component from moving (Collins English Dictionary Complete & Unabridged 10th Edition) . From the definition, retainer is a component
that attached the structures so that it will e in placed. This sub chapter will explain
about the retainer for automotive and mechanical discipline to produce.
6
2.1.1
Automotive retainer
In the automotive application, the retainer allows the use of components car such as
at a body panel as cited by (Purcell, 1978). The retainer comprises a strip attached to
the support structure and is conFigured to hold the body panel. Typically in the fuel
tank, pipe filler oil and body car are widely used.
2.1.1.1 Automotive retainer at fuel tank
Automotive oil pump
fixing ring was invented and shown in Figure 2.1
("Automotive oil pump fixing ring" 2013)). It provides the design of automotive oil
pump which is attached at fixed ring set on the upper tank. Existing car fixed ring
mostly have a steel ring with bolt hole circle on the plate and then fitted with bolts.
Figure 2.1 : A perspective view of
automotive oil pump fixing ring.
("Automotive oil pump fixing ring,"
2013)
In this design invention, there are some issues encountered for the existing fixed
wrong pump. The issues include the work piece operation, the part is easy to loose
and remove, low processing efficiency and high production costs, the retainer ring is
7
not quite to locate the oil pump, impede to ensure the accuracy of the assembly and
operational effectiveness, the stability is poor and the quality of the product is
different. In the technical problem, the utility model is implemented to achieve a
simple assembly operation and assembly of high precision purposes. To solve this
problem, the utility model approaches such as provided a car fixed ring pumps
including pumps fixed ring body, the body of the pump unalterable ring is provided
on the upper tank, the pump oil pump is provided on the cap retainer ring body
between the pump body and the stationary ring pump gland bolt and spot by spot
welding nuts.
2.1.1.2 Automotive retainer at pipe filler oil
Craig and Cupp (1983) invented the support of the fuel fill pipe for an automotive
type fuel tank. Moreover, it relates to a retainer that resists fill pipe withdrawal as
well as supports and locates the lower end of the fill pipe relative to the fuel tank. A
partially exploded view of the fuel tank filler pipe retainer is illustrated in Figure 2.2
as follows.
Figure 2.2 : Aperspective view of fuel tank
filler pipe retainer. (Craig & Cupp, 1983)
8
Pengeluaran semasa untuk penahan automotif dalam industri adalah melalui kaedah
proses konvensional. Proses ini melibatkan penggunaan operasi manual bagi mesin
penekanan besar dan jig. Pendekatan ini memerlukan penglibatan yang tinggi
daripada pekerja di bahagian pengeluaran. Akibatnya, masa kitaran yang diperlukan
lebih panjang untuk melengkapkan proses tersebut. Keadaan ini secara tidak
langsung akan mengurangkan kadar pengeluaran. Operasi manual dalam pendekatan
ini juga menyebabkan kos buruh yang lebih tinggi. Bagi mengatasi isu-isu ini,
mengautomasikan pengeluaran penahan automotif dilihat sebagai satu pendekatan
yang berpotensi. Idea utama projek ini adalah mencadangkan satu konsep reka
bentuk sistem automasi untuk pengeluaran penahan automotif. Konsep ini
mencadangkan penggunaan mekanisme pengindeksan berputar. Tiga peringkat akan
terlibat dalam projek ini. Pertama, ia melibatkan kajian tentang sistem pengeluaran
yang berkaitan. Kajian ini adalah untuk mendapatkan maklumat yang berasas tentang
jenis penahan automotif, pengeluaran penahan automotif di dalam tangki bahan api,
pendekatan pemindahan bahan dalam sistem pengeluaran, peralatan dalam reka
bentuk sistem pembuatan serta analisis mekanisme pengindeksan putar untuk sistem
pengeluaran automatik. Peringkat kedua ialah peringkat reka bentuk. Reka bentuk
dan simulasi proses sistem automatik yang dibangunkan akan melibatkan
penggunaan perisian CATIA. Peringkat akhir melibatkan dengan simulasi dan
analisis hasil simulasi. Apabila sistem pengeluaran automatik telah direka, proses
analisis akan dilakukan dengan menggunakan perisian SolidWorks. Analisis ini akan
melibatkan perbandingan menyeluruh pada masa kitaran semasa dan kadar
pengeluaran dengan versi automasi yang dicadangkan. Keputusan dijangka akan
meningkatkan kitaran masa dan juga kadar pengeluaran. Apabila semua siap,
pendekatan sistem pengeluaran automatik dalam menghasilkan penahan automotif
diharap dapat memberi manfaat kepada industri.
i
ABSTRACT
The current production of automotive retainer in the industry is through conventional
process. The process involves the use of manual operation of huge stamping
machines and its jigs. This approach requires high involvement of workers in the
production line. As a consequence, longer cycle time is required to complete the
process. This situation will indirectly lower the production rate. The manual
operation in this approach also indicates higher labour cost. To overcome these
issues, automating the production of automotive retainer is seen as a potential
approach. The main idea of this project is to propose a design concept of automation
system for the production of the automotive retainer. The propose concept include
the utilization of rotary indexing mechanism. Three stages were involved in this
project. Firstly, it involves the study of the related production systems. The study
involving reviews on the related production system has been included in this project.
The review is to gain the information based on the type of automotive retainer, the
production of the automotive retainer in fuel tank, material transfer approach in the
production system, tools in design of manufacturing system as well as analysis of the
rotary indexing mechanism for automated production systems. The second stage is
the design stage. The design and simulation process of the developed automated
system involved the use of CATIA software. The final stage involves with the
simulation and analysis of the simulation outcomes. Once the automated production
system has been designed, the analysis process is performed using SolidWorks
software. This analysis include a thorough comparison on the current cycle time and
production rate with the proposed automation version. The results show the
improvement of the cycle time as well as the production rate. The outcome of this
new automated approach in producing the automotive retainer is hoped to benefit the
industry in the future.
ii
DEDICATION
To my beloved parents Abd Rashid Jubari and Hasnah Mohd Amin, my supportive
siblings and my fellow friends,I love u all.
iii
AKNOWLEDGEMENT
Bismillahirrahmanirrahim. With the name of Allah the most Gracious and the most
Merciful.
First of all, I would like to thank Allah for giving me the strength to get this paper
done. I would like to express my utmost appreciation to Dr. Muhamad Arfauz bin A
Rahman who is my final year project supervisor. The supervision and support that he
gave truly help the progression and smoothness of completing this project. Not to
mention that all my friends those have been helping me in completing this research
and my beloved parents that gives all their support in completing my project.
iv
TABLE OF CONTENTS
Abstrak
i
Abstract
ii
Dedication
iii
Aknowledgement
iv
Table of Content
v
List of Tables
viii
List of Figures
ix
List Abbreviations, Symbols and Nomenclatures
xii
CHAPTER 1 : INTRODUCTION
1
1.1
Background
1
1.2
Problem statement
3
1.3
Objectives of Project
4
1.4
Scopes and Limitations of Project
4
1.5
Structure of the Report
5
CHAPTER 2 : LITERATURE REVIEW
6
2.1
Retainer
6
2.1.1
Automotive retainer
7
2.1.1.1 Automotive retainer at fuel tank
7
2.1.1.2 Automotive retainer at pipe filter oil
8
2.1.1.3 Automotive retainer at body car
9
2.1.2 Retainer in other application
2.2
9
Production of the automotive retainer in fuel tank
10
2.2.1
Stamping process
11
2.2.2
Tapping process
12
2.2.3
Assembly process
13
2.2.4
Manual production process
14
v
Automated production process
14
Material transfer in production system
15
2.3.1
Rotary indexing mechanism
15
2.3.2
In-line transfer
17
2.3.3
Robot
18
2.2.5
2.3
2.4
2.5
Tools in design and analysis of manufacturing process
19
2.4.1
CATIA software
19
2.4.2
SolidWorks software
20
2.4.3
Arena software
21
Analysis of the rotary indexing mechanism for automated production
22
process
2.6
2.5.1
Cycle time
22
2.5.2
Production rate
23
Concluding remarks
24
CHAPTER 3 : METHODOLOGY
25
3.1
Introduction
25
3.2
Project flowchart and gantt chart
25
3.3
Review of the current production process
27
3.4
Study and analysis the current production process
28
3.5
Determination the suiTable automated production process
29
3.5.1
Flow process in automated system
31
3.5.2
Flow process for mold during automated process approached
34
3.6
Design of the automated production process
36
3.7
Simulation of automated production propose using SolidWorks
37
3.7.1
38
3.8
3.9
Motion simulation of automated process
3.7.2
User interface in motion simulation
40
3.7.3
Analysis of motion simulation
41
Analysis of the automated production process
42
3.8.1
Determination of cycle time
42
3.8.2
Computation of production rate
42
Summary of chapter 3
42
vi
CHAPTER 4 : RESULT, ANALYSIS AND DISCUSSION
43
4.1
Engineering design
43
4.1.1
Part design
43
4.1.2
Assembly design
56
4.1.2.1 Complete assembly design of the stamping
machine
56
4.1.2.2 Complete assembly design of the automatic stamping
machine
57
4.1.2.3 Complete assembly design of the rotary
table
58
4.1.2.4 Complete assembly design of the magazine
table
59
4.1.2.5 Complete assembly design of the mold
section 1
59
4.1.2.6 Complete assembly design of the mold section
2
60
4.1.2.7 Complete assembly design of the mold section
60
3
4.1.2.8 Complete assembly design of the plant layout for automation
production line
4.2
4.3
61
Cycle time
62
4.2.1
Conventional process
62
4.2.2
Automated process
67
Analysis
70
CHAPTER 5 : CONCLUSION AND RECOMMENDATION
74
5.1
Conclusion
74
5.2
Recommendation for future research
75
REFERENCES
76
APPENDICES
79
vii
LIST OF TABLES
3.1 The shortcut button in motion tool bar.
41
4.1 Individual parts of the stamping machine.
44
4.2 Individual parts of the Automatic tapping machine.
45
4.3 Individual parts of the Automatic tapping machine. (continued)
46
4.4 Individual parts of the rotary table.
47
4.5 Individual parts of the rotary table. (continued)
48
4.6 Individual parts of the rotary table. (continued)
49
4.7 Individual parts of the magazine table.
50
4.8 Individual parts of the magazine table. (continued)
51
4.9 Individual parts of the mold section 1.
52
4.10 Individual parts of the mold section 1. (continued)
53
4.11 Individual parts of mold section 2.
54
4.12 Individual parts of mold section 3.
55
4.13 Cycle time of conventional process for automotive retainer
63
4.14 Cycle time of conventional process for automotive retainer
64
4.15 Cycle time of conventional process for automotive retainer
65
4.16 Average of cycle time for Conventional process.
66
4.17 Cycle time of automated process for automotive retainer
67
4.18 Average of cycle time for automated process approached.
70
4.19 Total cycle time of the production process.
70
4.20 Production rate of types production process.
71
viii
LIST OF FIGURES
1.1 Complete part of Automotive retainer (Sourse : United
1
1.2 Fuel tank upper that assembled with automotive retainer. (Source : United
Vehicles Industries Sdn. Bhd.)
2
2.1 A perspective view of automotive oil pump fixing ring. ("Automotive oil pump
fixing ring," 2013)
2.2 Aperspective view of fuel tank filler pipe retainer. (Craig & Cupp, 1983)
7
8
2.3 The detail design and application of retainer ball bearing. (Principle
Engineering)
10
2.4 The detail process and shaped for stamping process. (Dalessandro, Lorenz, &
Carr, 1998)
12
2.5 The view of threading fitting. (Groh, 1965)
13
2.6 The geneva mechanism. (Choubey & Rao, 1983)
16
2.7 The perspective view of an improved cross bar transfer press. (Bruns, 1993) 17
2.8 Robotic press machine. (Vieth R, 1999)
18
2.9 The icon of the CATIA Software. (Source : Internet)
19
2.10 Optimal part-programming in industry. (Source :
http://www.flowwaterjet.com/en.aspx)
20
2.11 The Arenasoftware. (Source : Internet)
21
3.1 Project flowchart
26
3.2 Stamping process cycle time study. (Source : United Vehicles Industries Sdn.
Bhd.)
28
3.3 Stamping process cycle time study. (Source : United Vehicles Industries Sdn.
Bhd.)
29
3.4 Rotary indexing mechanism. (Groover, 2008)
30
3.5 The proposed design layout.
31
3.6 The raw material.
32
3.7 Blanking process.
32
3.8 Chemfering process.
32
3.9 Pierching process.
33
3.10 Form/Embossing process
33
ix
3.11 Tapping process.
33
3.12 Process flow for the stamping machine at section 1.
34
3.13 Process flow for stamping machine at section 2.
35
3.14 Process flow for tapping machine at section 3.
35
3.15 The list of types for selection window.
36
3.16 The file selection.
37
3.17 The assembly workbench window.
37
3.18 Ground part for the floor of automated system approached.
39
3.19 Moving part for sub assembly in automated system approached.
39
3.20 Motion manager in the SolidWorks.
40
3.21 Time line area for motion analysis.
41
4.1 3D view of body stamping machine.
44
4.2 3D view of shaft stamping.
44
4.3 3D view of platform.
44
4.4 3D view of table.
45
4.5 3D view of motor.
45
4.6 3D view of shaft stamping machine.
45
4.7 3D view of spindle head.
46
4.8 3D view of tapper.
46
4.9 3D view of platform.
46
4.10 3D view of table.
47
4.11 3D view of rotary platform.
47
4.12 3D view of bracket cylinder.
47
4.13 3D view of big cylinder.
48
4.14 3D view of small cylinder.
48
4.15 3D view of long shaft.
48
4.16 3D view of short shaft.
49
4.17 3D view of small bracket.
49
4.18 3D view of end tool gripper.
49
4.19 3D view of table.
50
4.20 3D view of feed track.
50
4.21 3D view of bracket.
50
4.22 3D view of cylinder actuator.
51
x
4.23 3D view of shaft.
51
4.24 3D view of repellent.
51
4.25 3D view of bottom mold.
52
4.26 3D view of bottom die.
52
4.27 3D view of top mold.
52
4.28 3D view of big stripper.
53
4.29 3D view of small stripper.
53
4.30 3D view of bottom mold.
54
4.31 3D view of die.
54
4.32 3D view of top mold.
54
4.33 3D view of bottom mold.
55
4.34 3D view of jig.
55
4.35 Isometric view of the stamping machine assembly.
56
4.36 Isometric view of the automatic tapping machine.
57
4.37 Isometric view of the rotary Table.
58
4.38 Isometric view of the magazine Table.
59
4.39 Isometric view of the mold section 1.
59
4.40 Isometric view of the mold section 2.
60
4.41 Isometric view of the mold section 3.
60
4.42 Schematic view of the plant layout.
61
4.43 Bar graph for the production rate of different process approached.
72
xi
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
CATIA
-
Computer aided three-dimensional interactive application
AMS
-
Automated manufacturing system
CAD
-
Computer aided drawing
ICG
-
Interactive computer graphics
3D
-
Three dimensional
CAM
-
Computer aided manufacturing
CAE
-
Computer aided engineering
FMS
-
Flexible manufacturing system
DOF
-
Degree of freedom
IGS
-
Initial Graphic Specifications
xii
1 CHAPTER 1
INTRODUCTION
1.1 Background
In manufacturing the automotive fuel tank, there are few child parts required and
used to complete the construction of one fuel tank. The child parts that are assembled
in the fuel tank includes the tube breather, pipe fuel inlet, plate Fuel Tank separating,
sub-part tank fuel, Support Fuel sub-tank, Reinforcement fuel tank upper and clamp.
One of the prominent and important child parts is the bracket. The bracket is known
as an automotive retainer that uses to attach the fuel pump assembly. The automotive
retainer is assembled at the upper fuel tank at the lid of the fuel pump assembly.
Figure 1.1 and Figure 1.2 below show the automotive retainer in the fuel tank.
Figure 1.1 : Complete part of Automotive retainer (Sourse : United
Vehicles Industries Sdn. Bhd.)
1
Small
diameter size
for retainer
Big diameter
size for
retainer
Figure 1.2: Fuel tank upper that assembled with automotive retainer.
(Source : United Vehicles Industries Sdn. Bhd.)
From the Figure 1.2, the dimension sizes of the automotive retainer is divided into
two sizes. The big size dimension is attached at the center of fuel tank while the
smaller size is at the edge of the fuel tank. The function is same as a bracket which
is to attach the pump oil fuel and the tube of pump oil fuel.
In order to produce the parts of the fuel tank, the appropriate process manufacturing,
material selection and manufacturing system approach is concerned to get a better
fuel tank in case for the quality of the product. This is because the automotive fuel
tank is the safety product used by users. The production of the fuel tank needs to be
of high quality manufacturing process involving the child part, system production
and quality inspection. The material used to produce the fuel tank is made of sheet
metal. This sheet metal is shaped using stamping machine.
2
The production rate of automotive retainer is important to make sure the part is not
released before the assembly process occurs. The production rate of these parts must
be consistent that will be effect the process cycles time, the manufacturing stamping
process and the raw material. The process stamping that involved in the several types
such as the blanking process, chamfering process, form/embossing process, sheaving
process, piercing process, flattening process and tapping process.
In this industry, the current production process of automotive retainer is using the big
stamping machine and the conventional tooling. For examples, the process used the
stamping machine is also used for producing the retainer and other process to achieve
the desired parts. In addition, the mold and die can have changed to produce the other
parts as well as follow the company production planning. The operation of the
stamping machine needs at least one or two operators to operate the stamping
machine which includes the material input and output. After the stamping process
finished, the next process will be followed.
1.2 Problem statement
At present, the current production line approach used in the industry for the
production of the automotive retainer is through the conventional process. Typically
in the conventional process of an automotive retainer, stamping machine is widely
used. This is because of the large size of the stamping machine that is able to produce
this part. Hence, this will change the process method of stamping machine for
another process part. In brief, the problems identified due to the conventional
production line are as follows:
(a)
Longer cycle time to complete the process.
(b)
Lower production rate.
(c)
Higher labor cost increase to operate the production.
3
To overcome the elaborated issues, automated production system is seen as a
potential replacement system. The company can improve the production rate of the
automotive retainer through the design of the automated production line and reduce
the cycle time of the process.
1.3 Objectives of Project
To complete this project, three objectives have been identified. The objectives of this
project are:
(a)
To review and analyze the current production approach of the automotive
retainer in industry.
(b)
To propose the design conceptual of automating the production of the
automotive retainer using rotary indexing mechanism.
(c)
To analyze the cycles time and production rate for the proposed automated
production approach.
1.4 Scopes and Limitations of Project
The main idea of this project is to automate the production of the automotive
retainer. The proposed mechanism for this project will utilize the rotary indexing
mechanism. In this project, CATIA software and SolidWorks software will be used
to design the propose automated production line. Once the production line has been
designed, analysis of the cycle time will be analysed for the process involving both
the current method and the automated method will be performed.
Due to time constraint and the limitation of the software, this project does not
encompass on the design of the jig and fixtures for the handling of the retainer parts.
For the purpose of this project, the cycle time is calculated based on the material
handling of the input until end of the production line process.
4
1.5 Structure of the Report
The report is organized into five chapters. Chapter 1 will introduces the project
which includes background of project, problem statement, objectives to be achieved
throughout the project, scopes, as well as the limitation of the project.
Chapter 2, literature review begins by discussing several terms related to automated
production of the automotive parts, especially for retainer fuel tank, which is
followed by the system types of automated production that suiTable for the process
involved and the types of the material transfer mechanism on available design.
Chapter 3, methodology chapter discusses the method employed upon completing the
project. Mixed methodologies comprising qualitative and quantitative approached are
used to gather data. Flowcharts also will be shown for this chapter. Project design
and analysis are elaborate more to get the outcomes of the design of the production.
The simulation the automated production process will be created and analysed to get
the quantitative data such as the standard cycle time.
Chapter 4 is about the result, analysis and discussion with will discuss the outcomes
of the design and analysis of the automated production line, process selection to be
automated for appropriate process, engineering concept for manufacturing
production and the quantitative data of the cycle time process.
Chapter 5, the conclusion and recommendation chapter state the findings of the study
and discusses its implications. This study draws its conclusion primarily for the
design of automated production line as well as the analysis the time cycle process for
thisproject.
5
2 CHAPTER 2
LITERATURE REVIEW
This chapter summarizes the current state of knowledge and information about the
automating production of the automotive retainer using the rotary indexing
mechanism. The most important part of this chapter is the review of several scope of
the automotive retainer. Related issues regarding the production process system
includes the comparison between the automated process and the conventional
process. The review of cycle time and production rate of the production is also being
discussed. The basic idea of the material transfer in production process system is also
included. At the end of this chapter, there will be brief information of the design and
simulation of the automated process production which is created by using either
CATIA or SolidWorks software is included in this chapter.
2.1 Retainer
The retainer is defined as “a clip, frame or similar device that prevents a part of a
machine, engine and other component from moving (Collins English Dictionary Complete & Unabridged 10th Edition) . From the definition, retainer is a component
that attached the structures so that it will e in placed. This sub chapter will explain
about the retainer for automotive and mechanical discipline to produce.
6
2.1.1
Automotive retainer
In the automotive application, the retainer allows the use of components car such as
at a body panel as cited by (Purcell, 1978). The retainer comprises a strip attached to
the support structure and is conFigured to hold the body panel. Typically in the fuel
tank, pipe filler oil and body car are widely used.
2.1.1.1 Automotive retainer at fuel tank
Automotive oil pump
fixing ring was invented and shown in Figure 2.1
("Automotive oil pump fixing ring" 2013)). It provides the design of automotive oil
pump which is attached at fixed ring set on the upper tank. Existing car fixed ring
mostly have a steel ring with bolt hole circle on the plate and then fitted with bolts.
Figure 2.1 : A perspective view of
automotive oil pump fixing ring.
("Automotive oil pump fixing ring,"
2013)
In this design invention, there are some issues encountered for the existing fixed
wrong pump. The issues include the work piece operation, the part is easy to loose
and remove, low processing efficiency and high production costs, the retainer ring is
7
not quite to locate the oil pump, impede to ensure the accuracy of the assembly and
operational effectiveness, the stability is poor and the quality of the product is
different. In the technical problem, the utility model is implemented to achieve a
simple assembly operation and assembly of high precision purposes. To solve this
problem, the utility model approaches such as provided a car fixed ring pumps
including pumps fixed ring body, the body of the pump unalterable ring is provided
on the upper tank, the pump oil pump is provided on the cap retainer ring body
between the pump body and the stationary ring pump gland bolt and spot by spot
welding nuts.
2.1.1.2 Automotive retainer at pipe filler oil
Craig and Cupp (1983) invented the support of the fuel fill pipe for an automotive
type fuel tank. Moreover, it relates to a retainer that resists fill pipe withdrawal as
well as supports and locates the lower end of the fill pipe relative to the fuel tank. A
partially exploded view of the fuel tank filler pipe retainer is illustrated in Figure 2.2
as follows.
Figure 2.2 : Aperspective view of fuel tank
filler pipe retainer. (Craig & Cupp, 1983)
8