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DESIGN APPROACH IN THE DEVELOPMENT PROCESS OF PLASTIC PARTS FROM MECHATRONICS EQUIPMENT FOR SERIAL PRODUCTION
Aleksandar Stefanov Abstract: The increasing of the level of complexity of the mechatronics products and the continuous growing of the customers expectations make the development process of the mechatronics product very complicated task. The requirements become even stronger, when the product has to be designed for serial production. Achieving the customer requirements is possible only when complete, fully described design approach is applied in the development process. Keywords: mechatronics product, development process, plastic parts 1. Introduction In the design processes of the mechatronics equipment achieving successful results is only possible when a complete design approach is followed. The design approach has to contain separate design steps and their consequence and description, also they have to be predefined and adapted to the current application. The mechatronics design approach provides this possibility, it is an iterative and sequenced approach, applied in a variety of applications. Its common structure is based on a sequenced V-shaped cycles, which contains the predefined design substeps. With the completion of each sub-step the level of maturity of the product is increased. This common structure gives the global description of the design process, therefore in order to increase its efficiency it is necessary the approach to be adapted for the current application. 2. Common structure of the mechatronics design approach The mechatronics design approach provides the possibility the mechanical, electronical and control system to be designed together, taking into account the influences between them [5]. This approach is flexible and iterative, it also uses a sequence of V-cycles, containing the predefined sub-steps. The number and type of the sub-steps in this design approach is variable and it is adapted to the current application. By using the initially defined customer requirements and technological information the sub-steps from the system, sub-system and component level are completed. In the system integration level, the concept of the product is defined. Also the technological and customer requirements are taken into account.

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The product sub-elements and its detailed features are described in the system design sub-level starting the element virtualization. At the component level, each component is developed in detail.

Fig. 1 Common structure of the mechatronics V-cycle [5]

As a result, the virtual prototype of the product is achieved. Using the data from the virtual prototype, the system integration is started, following the sub-steps of the component, sub-system and system level. According to the data from the virtual model, the separated elements are analyzed and integrated through the upper level. During the system integration different analysis are completed, according to the virtual prototype data, the FEM analysis, also tolerance and clash analysis of the parts are provided. At the end of the cycle the real prototype of the product is made. It is validated and verified according to the initially defined requirements. Each cycle brings information from the product development process, according to this information the modifications of the product in the in the next V-cycle can be made. Usually the design process contains more than one V-cycle. The number of the V-cycles is defined by a designer, and is depending on his knowledge, experience and complexity of the tasks [5]. The more the sub-steps are completed, the more the Vcycle is finished, the more the level of maturity of the product is increased. In the references exists various examples of design approaches for mechatronics products, also there are design approaches for designing of the plastic parts [2,3,6], but there was not found approach, that describes the sub-steps of the development process for plastic parts applied in mechatronics equipment, that has to be designed for serial production. Complete design approach for a plastic part is developed using the mechatronics design process. The plastic part is used in a mechatronics product which is designed for serial production [1].

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3. Design approach in the development process of plastic part from mechatronic product for serial production. The design process consists of three main V-cycles. Their sequence describes the increase of the level of maturity of the product. The V-cycle I (fig.2) contains the initial values of the design parameters of the product, customer requirements, shape and overall dimensions etc. In the next sub-step is described the manufacturing concept of the separated parts. Based on the initial A-surfaces the features of the separated parts are designed. At the end of the system design, the virtual prototype of the product is made.

Fig. 2 Mechatronics design approach V-cycle I

Based on the virtual prototype different analysis is accomplished FEM analysis, DFMEA analysis, etc. The results from these analysis give only the initial direction for next structural modifications. At the end of the cycle a Rapid prototyping samples of the product are made. The structure of the V-cycle II is shown on the fig.3. It is similar to the V-cycle I, but the level of maturity of the product increases. Due to the results of the tests of the prototypes from cycle I, the modifications of the structure are made. The main concept of the structure remains the same when there are no special needs for its change. After the virtual prototype modifications, the draft and tolerance analysis are completed. Using the modified virtual prototype the FEM analysis is also provided. In this cycle thermal tests and electromagnetic compatibility tests are provided, because this cycle ends with a completed product that has to be fully functional. Cycle ends with the manufacturing of small series of the product, ready for testing and being validated.

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Fig. 3 Mechatronic approach V-cycle II

When the results from the verification and validation of the cycle II prototypes are acceptable, the V-cycle III is started. Its structure is shown on the fig.4.

Fig. 4 Mechatronics approach V-cycle III

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In Cycle III the level of maturity of the product is biggest, therefore the construction modifications are minimal. Only the analysis and measurements for check are provided. The data for serial production is prepared and at the end of the cycle the serial tool is made. Results: The developed approach describes the separated design and development sub-steps of the mechanical plastic parts of mechatronics product. This approach is implemented in the design process of mechatronics automotive equipment, but it also can be applied in different design processes related to the design of plastic parts. 4. Conclusions The main V-cycles of the design process are described The main sub-steps of the design and development processes are defined The developed approach is applied in various applications related to the automotive mechatronics equipment The approach purpose is increased because it can be applicable in various design processes, related to the design of plastic parts References: 1. , ., ( ), , , 2007 2. Consultek : Designing plastic parts, Finite Element Analysis, FEA, http://www.consultekusa.com/design.html 3. Gausmeier, J., Moehringer, S., New Guideline VDI 2206 a flexible procedure model for the design of mechatronic systems, proceedings of 14th International Conference of Engineering Design ICED03, p.599-600, 2003 http://papers.designsociety.org/new_guideline_vdi_2206a_flexible_procedure_model_for_the_design_of_mechatronic_systems.paper.23949.h tm 4. Isermann, R., Mechatronic Design approach, in Bishop, R.H. (Ed): The Mechatronics Handbook, CRC Press, Boca Raton, Section I: Overview of mechatronics, ch. 2, p. 3, 2002 5. Mesyov, Y., Neshkov T., Mechatronics report, TU-Sofia, ELDE, 2005 6. Schneider, K., Plastic Parts Design, AutoDesk, http://mfgcommunity. autodesk.com/files/blog/kevin/Plastic%20Parts%20Design%20MA32-2.pdf, 11.2006. Author: Aleksandar Georgiev Stefanov, PhD, TU-Sofia, dept. ADPE, fac.MEF, Technical University of Sofia, Bulgaria, bul. Kl. Ohridski 8, phone: +359/887 83 50 22, e-mail: spindle@abv.bg