Design & Analysis Of Multi Led Machine Fixture Using Cad Tools.
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DESIGN AND ANALYSIS OF MULTI LED MACHINE FIXTURE
USING CAD TOOLS
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(ManufacturingDesign) with Honours.
FACULTY OF MANUFACTURING ENGINEERING
2009
UTeM Library (Pind.112007)
TAJUK: Desien and Analysis Of Multi Led Machine Fixture Usinq CAD Tool
SESl PENGAJIAN: 2008109
Saya NURUL SAADAH BINTI ABDUL RAHlM (8050610226)
mengaku membenarkan laporan PSM ini disimpan di Perpustakaan Universiti
Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak mitik Universiti Teknikal Malaysia Melaka dan penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat satinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. ""Sila tandakan (4)
(Mengandungi maklwnat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMl 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasilbadan di mana penyelidikan dijalankan)
Disahkan oleh:
(TANDATANGAN PENYELIA)
No. 15, Jln Rawai 19141,
Tarikh: 13 OKTOBER 2008
~~w
Kejuruteraan
universitiTekmkal MakYs'a
Tarikh:
s/d9
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
comfortable at worker‟s sitting and standing position. Otherwise this machine is easily
movable and the design meet quality standard; i.e. machine height and working coverage
competent done by machine.
CAD tools have been used which are COSMOSXpress
and ANSYS. The new fixture has three new main parts which are cover, base and
cutter. The cover is a place to cut and bend the LEDs, the base is to hold the LED and
the cutter function is to cut the LEDs. In addition, the safety factor for base has been
successfully determined as safe part and it is suitable for 2000 life cycle. As a results
new fixture machine has been developed.
i
ABSTRAK
Projek ini bertujuan untuk merekacipta dan menganalisa sebuah mesin “Multi LED
Machine Fixture” dengan menggunakan perisian CAD. Projek ini dijalankan untuk
menghasilkan satu lagi mesin baru bagi aplikasi potong dan bengkok secara serentak
untuk industri kecil elektronik.
Mesin ini mempunyai banyak kelebihan antaranya
seperti rekaan geometri mesin yang akan dihasilkan tidak terlalu besar dan
ketinggiannya mengikut kesesuaian pekerja sama ada dalam keadaan duduk mahupun
berdiri. Selain daripada itu, produk ini juga adalah jenis mudah alih dan ia direka bentuk
untuk memenuhi piawaian kualiti, contohnya seperti had ketinggian mesin dan liputan
kerja yang mampu dilakukan mesin.
COSMOSXpress dan ANSYS.
Perisian CAD digunakan antaranya ialah
Fixture baru ini mempunya tiga bahagian utama
antaranya ialah penutup, tapak dan pemotong. Penutup adalah tempat untuk memotong
dan membengkokkan kaki LED, tapak pula digunakan untuk menahan LED dan fungsi
pemotong adalah untuk memotong LED. Dalam pada itu, faktor keselamatan pada tapak
adalah selamat dan ianya sesuai digunakan sehingga 2000 penggunann. Keputusannya
mesin fixture baru telah dihasilkan.
ii
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.
Lastly, your supports are highly appreciated and very meaningful to me.
iii
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.
Thank You
iv
TABLE OF CONTENT
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Content
v
List of Tables
x
List of Figures
xii
List Abbreviations
xvi
1. INTRODUCTION
1
1.1
Background of Project
1
1.2
Problem Statement
3
1.3
Objectives
4
1.4
Scope of Project
4
1.5
Project Outline
4
2. LITERATURE REVIEW
6
2.1
Fixtures
6
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
2.2.4
Design Consideration of Work Holders
14
v
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
2.8.2
ANSYS
41
2.9
Machine Used
42
2.9.1
Rapid Prototype
42
2.9.2
Tool and Cutter Grinder
44
2.10
The Product to be Developed – Multi LED Machine Fixture
45
2.10.1
Definition of Multi LED Machine Fixture
45
2.10.2
History of Multi LED Machine Fixture
46
vi
3. METHODOLOGY
47
3.1
Flow Chart for PSM 1
48
3.1.1
Explanation on flow chart for PSM 1
48
3.2
Flow Chart for PSM 2
50
3.2.1
Explanation on flow chart for PSM 2
50
3.3
Gantt Chart
52
3.3.1
Progress Report for PSM 1
52
3.3.2
Progress Report for PSM2
53
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
4.8.1
Multi LED Machine Fixture Operation
90
vii
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
6. CONCLUSION
123
viii
REFERENCES
125
APPENDIX
ix
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
4.14
Cover Property
96
4.15
Material for Base
97
4.16
Restraint for Base
98
4.17
Loads for Base
98
4.18
Mesh Properties for Base
98
4.19
Solver Information for Base
98
4.20
Stress Results for Base
99
x
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
111
4.41
Definition
111
4.42
Results
111
4.43
"Structural Steel" Constant Properties.
112
5.1
Alternating Stress
120
5.2
Strain-Life Parameters
121
xi
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
40
deformations with Code-Aster
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
4.2
Concept design 1
58
xii
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
4.24
Orient Icon
78
4.25
STL Rotate
78
4.26
Part Use Orient STL Button
79
4.27
Slice Icon
79
4.28
Slice Curves for the Part
80
4.29
Create Support Button
80
4.30
Creating Support
81
4.31
Toolpath Button
81
4.32
Create Toolpath for the part.
82
4.33
Saving the Toolpath (CMB File)
82
xiii
4.34
Flag Button
83
4.35
Flag Shortcut Procedure
83
4.36
Rapid Processes
84
4.37
Tighten the rod
85
4.38
The wheel touches the rod
86
4.39
Technique to grind the rod face
86
4.40
Grinding area
87
4.41
Distance to be grind
87
4.42
The cutter
87
4.43
Cutter Wheel
88
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
5.3
Shear Stress.
119
xiv
5.4
Alternating Stress.
120
5.5
Strain Life Parameters
121
xv
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
lb
-
Pound
xvi
LED
-
Light Emitting Diode
MEC
-
Milwaukee Electronics
mm
-
millimeter
mm2
-
Millimeter Cubic
n
-
Number of Criteria
NX
-
Unigraphics
PCB
-
Printed Circuit Board
PLC
Programmed Logical Control
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
wi
-
Weighting for ith Criterion
WYSIWYG
-
What You See Is What You Get
xvii
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.
Malaysia is one of the leading electrical and electronic product exporters worldwide.
Almost 1000 companies in this industry are incorporated in Malaysia. The industry
includes major brands like Panasonic, Sony, Philips and Samsung and local brands
like I, MEC, Khind and Pensonic. The production range includes air-conditioners,
refrigerators, washing machines, vacuum cleaners, electric fans, instant water
heaters, rice cookers, blenders and microwave ovens. Malaysia is also a major
exporter of semiconductor devices, which accounted for over 30% of total electronic
exports in 2000. Malaysia is currently investing in R&D in order to expand its
1
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
condition.
The function of the machine is so effective to cut and bend in
2
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.
Furthermore, final element will be done by QFD. It is aimed for producing a better
quality product. In other word, it is a method for introducing quality right from
design stage to satisfy the users.
3
DESIGN AND ANALYSIS OF MULTI LED MACHINE FIXTURE
USING CAD TOOLS
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(ManufacturingDesign) with Honours.
FACULTY OF MANUFACTURING ENGINEERING
2009
UTeM Library (Pind.112007)
TAJUK: Desien and Analysis Of Multi Led Machine Fixture Usinq CAD Tool
SESl PENGAJIAN: 2008109
Saya NURUL SAADAH BINTI ABDUL RAHlM (8050610226)
mengaku membenarkan laporan PSM ini disimpan di Perpustakaan Universiti
Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Laporan PSM adalah hak mitik Universiti Teknikal Malaysia Melaka dan penulis.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis.
3. Perpustakaan dibenarkan membuat satinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi.
4. ""Sila tandakan (4)
(Mengandungi maklwnat yang berdarjah keselamatan
atau kepentingan Malaysia yang termaktub di dalam
AKTA RAHSIA RASMl 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan
oleh organisasilbadan di mana penyelidikan dijalankan)
Disahkan oleh:
(TANDATANGAN PENYELIA)
No. 15, Jln Rawai 19141,
Tarikh: 13 OKTOBER 2008
~~w
Kejuruteraan
universitiTekmkal MakYs'a
Tarikh:
s/d9
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
comfortable at worker‟s sitting and standing position. Otherwise this machine is easily
movable and the design meet quality standard; i.e. machine height and working coverage
competent done by machine.
CAD tools have been used which are COSMOSXpress
and ANSYS. The new fixture has three new main parts which are cover, base and
cutter. The cover is a place to cut and bend the LEDs, the base is to hold the LED and
the cutter function is to cut the LEDs. In addition, the safety factor for base has been
successfully determined as safe part and it is suitable for 2000 life cycle. As a results
new fixture machine has been developed.
i
ABSTRAK
Projek ini bertujuan untuk merekacipta dan menganalisa sebuah mesin “Multi LED
Machine Fixture” dengan menggunakan perisian CAD. Projek ini dijalankan untuk
menghasilkan satu lagi mesin baru bagi aplikasi potong dan bengkok secara serentak
untuk industri kecil elektronik.
Mesin ini mempunyai banyak kelebihan antaranya
seperti rekaan geometri mesin yang akan dihasilkan tidak terlalu besar dan
ketinggiannya mengikut kesesuaian pekerja sama ada dalam keadaan duduk mahupun
berdiri. Selain daripada itu, produk ini juga adalah jenis mudah alih dan ia direka bentuk
untuk memenuhi piawaian kualiti, contohnya seperti had ketinggian mesin dan liputan
kerja yang mampu dilakukan mesin.
COSMOSXpress dan ANSYS.
Perisian CAD digunakan antaranya ialah
Fixture baru ini mempunya tiga bahagian utama
antaranya ialah penutup, tapak dan pemotong. Penutup adalah tempat untuk memotong
dan membengkokkan kaki LED, tapak pula digunakan untuk menahan LED dan fungsi
pemotong adalah untuk memotong LED. Dalam pada itu, faktor keselamatan pada tapak
adalah selamat dan ianya sesuai digunakan sehingga 2000 penggunann. Keputusannya
mesin fixture baru telah dihasilkan.
ii
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.
Lastly, your supports are highly appreciated and very meaningful to me.
iii
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.
Thank You
iv
TABLE OF CONTENT
Abstract
i
Abstrak
ii
Dedication
iii
Acknowledgement
iv
Table of Content
v
List of Tables
x
List of Figures
xii
List Abbreviations
xvi
1. INTRODUCTION
1
1.1
Background of Project
1
1.2
Problem Statement
3
1.3
Objectives
4
1.4
Scope of Project
4
1.5
Project Outline
4
2. LITERATURE REVIEW
6
2.1
Fixtures
6
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
2.2.4
Design Consideration of Work Holders
14
v
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
2.8.2
ANSYS
41
2.9
Machine Used
42
2.9.1
Rapid Prototype
42
2.9.2
Tool and Cutter Grinder
44
2.10
The Product to be Developed – Multi LED Machine Fixture
45
2.10.1
Definition of Multi LED Machine Fixture
45
2.10.2
History of Multi LED Machine Fixture
46
vi
3. METHODOLOGY
47
3.1
Flow Chart for PSM 1
48
3.1.1
Explanation on flow chart for PSM 1
48
3.2
Flow Chart for PSM 2
50
3.2.1
Explanation on flow chart for PSM 2
50
3.3
Gantt Chart
52
3.3.1
Progress Report for PSM 1
52
3.3.2
Progress Report for PSM2
53
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
4.8.1
Multi LED Machine Fixture Operation
90
vii
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
6. CONCLUSION
123
viii
REFERENCES
125
APPENDIX
ix
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
4.14
Cover Property
96
4.15
Material for Base
97
4.16
Restraint for Base
98
4.17
Loads for Base
98
4.18
Mesh Properties for Base
98
4.19
Solver Information for Base
98
4.20
Stress Results for Base
99
x
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
111
4.41
Definition
111
4.42
Results
111
4.43
"Structural Steel" Constant Properties.
112
5.1
Alternating Stress
120
5.2
Strain-Life Parameters
121
xi
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
40
deformations with Code-Aster
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
4.2
Concept design 1
58
xii
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
4.24
Orient Icon
78
4.25
STL Rotate
78
4.26
Part Use Orient STL Button
79
4.27
Slice Icon
79
4.28
Slice Curves for the Part
80
4.29
Create Support Button
80
4.30
Creating Support
81
4.31
Toolpath Button
81
4.32
Create Toolpath for the part.
82
4.33
Saving the Toolpath (CMB File)
82
xiii
4.34
Flag Button
83
4.35
Flag Shortcut Procedure
83
4.36
Rapid Processes
84
4.37
Tighten the rod
85
4.38
The wheel touches the rod
86
4.39
Technique to grind the rod face
86
4.40
Grinding area
87
4.41
Distance to be grind
87
4.42
The cutter
87
4.43
Cutter Wheel
88
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
5.3
Shear Stress.
119
xiv
5.4
Alternating Stress.
120
5.5
Strain Life Parameters
121
xv
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
lb
-
Pound
xvi
LED
-
Light Emitting Diode
MEC
-
Milwaukee Electronics
mm
-
millimeter
mm2
-
Millimeter Cubic
n
-
Number of Criteria
NX
-
Unigraphics
PCB
-
Printed Circuit Board
PLC
Programmed Logical Control
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
wi
-
Weighting for ith Criterion
WYSIWYG
-
What You See Is What You Get
xvii
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.
Malaysia is one of the leading electrical and electronic product exporters worldwide.
Almost 1000 companies in this industry are incorporated in Malaysia. The industry
includes major brands like Panasonic, Sony, Philips and Samsung and local brands
like I, MEC, Khind and Pensonic. The production range includes air-conditioners,
refrigerators, washing machines, vacuum cleaners, electric fans, instant water
heaters, rice cookers, blenders and microwave ovens. Malaysia is also a major
exporter of semiconductor devices, which accounted for over 30% of total electronic
exports in 2000. Malaysia is currently investing in R&D in order to expand its
1
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
condition.
The function of the machine is so effective to cut and bend in
2
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.
Furthermore, final element will be done by QFD. It is aimed for producing a better
quality product. In other word, it is a method for introducing quality right from
design stage to satisfy the users.
3