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

(Manufacturing Design) with Honours.

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 (805061 0226)

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 Mela ka dibenarkan mem buat salinan

untuk tu juan 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 d i mana penyelidikan dijalankan)

Disahkan oleh:

(TANDATANGAN PENYELIA)

No. 15, Jln Rawai 19141,

~~w

i

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

ii

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. Perisian CAD digunakan antaranya ialah

COSMOSXpress dan ANSYS. 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

iii

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.

iv

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.

v

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

vi

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

vii

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

viii

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

ix

REFERENCES 125

x

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

xi

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

4.41

_Definition

4.42

_Results

4.43 "Structural Steel" Constant Properties. 112

5.1 Alternating Stress 120

xii

LIST OF FIGURES

2.1 Plate Fixture 8

2.2 Angle-plate fixture 9

2.3 Modified angle-plate fixture 9

2.4 Various aspect of fixture design 11

2.5 Elementary Work Holder 13

2.6 Vise with hydraulic clamping 13

2.7 Locating and clamping principles 14

2.8 The twelve degrees of freedom 14

2.9 Human-Machine System 21

2.10 Standing adult man 24

2.11 Quality function deployment process 25

2.12 House of Quality 26

2.13 House of Quality Matrix 27

2.14 Hierarchical decomposition of selection criteria 32

2.15 SolidWorks Hierarchy 38

2.16 Nonlinear statistics analysis of a 3D structure subjected to plastic

deformations with Code-Aster

40

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

xiii

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

xiv

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

xv

5.4 Alternating Stress. 120

xvi

LIST OF ABBREVIATIONS

$ - Dollar

3D - Three-Dimensional

a - Lever Length

AG - Aktiengesellschaft (German Words: Domain)

BMW - Bayerische Motoren Werke

C++ - C Plus Plus

CA - Customer Attributes

CAD - Computer Aided Design

CAE - Computer Aided Engineering

CAM - Computer Aided Manufacturing

CATIA - Computer Aided Three Dimensional Interactive Application

CAx - Computer Aided Technologies

CFD - Counterfactual Definiteness

CNC - Computerized Numerical Control

dB - Decibel

DELMIA - Digital Enterprise Lean Manufacturing Interactive Application

Dr. - Doctor

E.g. - Example

En. - Encik (Sir)

etc - "and other things" or "and so on"

F - Human Force

FKP - Fakulti Kejuruteraan Pembuatan

HoQ - House of Quality

i.e. - Example

IBM - International Business Machines

in - Inch

kg - Kilogram

xvii LED - Light Emitting Diode

MEC - Milwaukee Electronics

mm - millimeter

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

1

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

2

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

3

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