daikin industries limited product development of room air-conditioners using solid edge takashi...
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DAIKIN Industries Limited
PRODUCT DEVELOPMENT OFROOM AIR-CONDITIONERS USING SOLID EDGE
Takashi MIYAWAKI
Daikin Industries Limited
Information Technology Advancement Center
October 14, 1999Solid Edge Second AnnualInternational User Group Conference
DAIKIN Industries Limited
Overview of DAIKIN http://www.star-net.or.jp/daikin/index_e.html
Air-conditioners for Store and BuildingRoom Air-conditioners
Company Profile• Number of Employees : About 8000• 1 Head Office and 4 Branch offices• 5 Manufacturing Plants• Related Company : 61 in Japan, 14 in the World (Belgian, Thailand, etc..)
Main Products• Air-conditioners and the Applications• Fluorine Chemical products• Computer Hardware and Software Sales
Exampleof
Air-conditioners
DAIKIN Industries Limited
History of Three Dimensional CAD Advancement in DAIKIN and Purpose of This Trial Project
First Step : Introduction Term (Up to the present)– In order to apply three dimensional CAD to Air-conditioner’s piping
design, system development using Pro/E was started from 1991.– Trial use and improvement of the system until 1994.– Release to user from 1995, and now it is used in the almost of main
developments of air-conditioners outdoor units. Second Step : For real use Term (Now)
– To enlarge the effectiveness of 3D Design, change the direction to full 3D design and start to reevaluate the 3D CAD system from 1997.
» Evaluation point : Ease of use, Well-balanced function of 2D and 3D,and Cost
– Solid Edge was selected best one of next CAD in June 1998.
Verification of Solid Edge FunctionVerification of Solid Edge Functionby Practical use in the product developmentby Practical use in the product development
Purpose of This Trial Project
DAIKIN Industries Limited
Details of Verification
Function verification– Function of 3D design for Air-conditioners– Performance speed– Reliability
Utility Verification– Decrease of learning time than the system before– 3D design of large and complex plastic parts in the real development
Effectiveness Verification of 3D design– Accuracy improvement of design, and Decrease of design time– Reduction of processing time of trial manufacture– Time Reduction of mold design
DAIKIN Industries Limited
Overview of Solid Edge Trial Project- Application to Product Development of Room Air-conditioners -
Features of Target Product– Drastic cost-cutting:
new type of shape/structure should be developed– Faster development by two months
3-D Design was the only solution
Action Overview– Consists of 200 parts– Including 5 very large parts: 1500 dimensions each– Four to five designers are working in a team– Using Solid Edge over the entire design process:
Conceptual Design through Generating Production Drawings
Room Air-conditioners Image(Previous Model)
DAIKIN Industries Limited
Theme in Applying 3-D Design
Effective modeling of Large and Complex plastic parts– Characteristics of Feature base modeler
» Advantage : Make the design efficient, Information Transmission of design Intent
Effective Approach in Series Design and Appropriation Design Transmit design intent correctly Avoid stupid mistake
» Problem : Handling of Large Part Features It takes a lot of time for searching and recalculating when feature editing
Suggestion of Function Based Modeling and Implementation
Establish of Efficient Three Dimensional Modeling Skill for Feature based Modeler
DAIKIN Industries Limited
About Function Based Modeling
Modeling by functional character rather than geometric
Large and Complex parts are multi-functional– structure could be simple and applicable to other models by dividing by
function– functions are usually to contain something
» air duct : contain air, drain-pan : receive water
Basic consideration– divide into parts by function and unit to be made shell– rough shaping to start– editing by cut/add should be done before shelling
DAIKIN Industries Limited
Parallel Approach and Sequential Approach of Function Based Modeling
– Parallel Approach» making parts and integration by linking with Assemble Layout» grouping by function
– Sequential Approach» sequential Link by Divide Parts or Insert Parts» grouping by modeling level
AssemblyAssemblyLayoutLayout
Control of ShapeFeature
FunctionPart
FunctionPart
FunctionPart
Assembly
Feature Feature
DesiredPart
Insertion for IntegrationPart
FeatureFeatureFeatureFeatureFeatureFeatureFeatureFeatureFeatureFeatureFeature
Part
FeatureFeatureFeatureFeatureFeatureFeatureFeatureFeatureFeatureFeatureFeature
Part
FeatureFeatureFeatureFeatureFeatureFeatureFeatureFeatureFeatureFeatureFeature
DesiredPart
ParallelApproach Sequential Approach
Insertion Insertion
DAIKIN Industries Limited
Implementation Result 1 : Concept Design by Solid Edge
Data Transferby e-mail
1/2 time compare to 2D design
6.5 days for modeling include OJT(On the Job Training)
Rapid Prototype
6 Days for processing( 1/2 time)
Integration two parts into oneand It is difficult to design by 2D
Existing product
Concept Design by Solid Edge
Result in Concept Design
Function : Utility :Effectiveness :
Function : Utility :Effectiveness :
DAIKIN Industries Limited
Implementation Result 2 : Detail Design by Solid Edge
Heat Exchanger Assembly
Fan Assembly
FrameAssembly
Electric ComponentAssembly
Air clean unitAir flow Assembly
Front Panel Assembly
Learning Time 2 or 3 days for basic 2 weeks for practical use
Learning Time 2 or 3 days for basic 2 weeks for practical use
Two kind offront panel
DAIKIN Industries Limited
Implementation Example of FBM (Function Based Modeling)- Parallel Approach on Frame Part -
Divide into parts as air path, motor cover, fix part on back face, drain pan, etc
Integration to one part byassembly insert
DAIKIN Industries Limited
Frame Part by FBM: Part Linkage with Assembly Layout
Generate parts by “Create In-place”, and Linking with Assemble Layout.
DAIKIN Industries Limited
Frame Part by FBM: Correspondence to Design Modification
Shape modification before shelling
DAIKIN Industries Limited
Frame Part by FBM: Shape Coordination after Integration
Screw boss : prepared longer than required as functional part. After assembled, protrusion is cut by Replace Face
DAIKIN Industries Limited
Example 2:Front Panel Parts - Parallel and Sequential approach -
DAIKIN Industries Limited
Front Panel Parts by FBM: Industrial Design Surface
Industrial Designer
Modeled the right half ofoutside shape of Front Panel
Integrate them by insertionto a part, and dividethe part into two parts using Divide by face
Generate the other side byInsert Part and Mirroring
Completion ofPanel Face
DAIKIN Industries Limited
Front Panel Parts by FBM: Detail Modeling 1
Detail Modeling (Outside)
Detail Modeling(Inside)
Feature grouping was done by Integration, Division, and Part insertion(FBM sequential approach)
DAIKIN Industries Limited
Front Panel Parts by FBM: Detail Modeling 2
Designer
Divide Part into upper slit portion and rollet portion (when Patterning is included, other operations tend to becomes abnormally slow.)
DAIKIN Industries Limited
Front Panel Parts by FBM: Detail Modeling 3
Almost symmetric each other but have slight differenceapplied Family of Parts ( with Suppress Feature)
Right and Left covers
DAIKIN Industries Limited
Front Panel Parts by FBM: Integration to one Part
Integrate into one part(FBM parallel approach)
DAIKIN Industries Limited
Effect of Three Dimensional Surface Modeling
Two types of panels are designed.
Shape parameters are defined using parametric dimensions
in Solid Edge.
Shape modified on theScreen
Not coordinatehere
Avoid mistake which will occur in case of two dimensional design
DAIKIN Industries Limited
Whole Image of the Product
DAIKIN Industries Limited
Result of Direct and Rapid Prototype from 3D Model
Effect– Realization of Drawing Less and Data Transfer by Internet
– Panel Parts : Accurate and Time Eliminate by NC Processing. Omission of ID Model making.
– Electric Component : Rapid Prototypes are very effective in these parts (small and complex)
– Inquiries from processors about model are Almost nothing
Subject– Rapid Prototype for Large Part like Frame (Accuracy and Strength is not enough for test model)
– It is difficult to transfer the modification portion when alternation because there is no drawing
– Prototype is made the same shape as 3D model even if there is a mistake (No check before prototype) -> Strong evaluation of 3D model before trial is needed
DrawingDesign2D
3DDesign
Inquire
Inquires Decrease
Modificationof mistake
Alternation
Alternation
Prototypemaking
Accuracy Improvement
Comparison between 2D and 3D about Front Panel PartsComparison between 2D and 3D about Front Panel Parts
Prototypemaking
DAIKIN Industries Limited
最後に
今回のプロジェクトで多くのサポートを頂き、またこのような発表の機会を与えていただいたユニグラフィックスソリューションの方々にお礼を申し上げます。
特にダイキンの要望を理解していただき、機能の実現をしていただいた David Hagood氏、また技術的な質問の受け答えから米国とのやりとりを含め各種の辛抱強いサポートを頂いた原さんに感謝します。