Product development of a gripping mechanism for a flexible 3D stretch bending machine for industrial applications - Exploring the concepts of set-based concurrent engineering

Abstract

High strength aluminum components are increasingly popular in the automotive industry. Development of novel manufacturing machines for these components is required to gain a competitive edge. An automotive parts manufacturer has previously constructed a flexible three-dimensional stretch bending machine for aluminum extrusions. The manufacturer is going to develop a new machine of similar design, but with a new gripping mechanism.

Set-based concurrent engineering (SBCE) is a design methodology which regards sets of design possibilities for each sub-system of the product. Sets refer simply to areas in the design space. This area is gradually narrowed through-out the development process by considering all aspects of the engineering effort concurrently. The sets converge slowly towards an intersection of each sub-system sets. This is intended to increase flexibility to optimise the system. SBCE is fairly new to western societies and requires more industrial case studies to gain credibility.

This paper presents a case study of SBCE at an automotive parts manufacturer regarding product development of a novel gripping mechanism for a new flexible threedimensional stretch bending machine. The researcher was co-located with the automotive parts manufacturer over a duration of four months to observe and interview selected employees.

A literature study of SBCE was conducted which identified principles, activities and a process model for the product development. Additionally, research gaps were identified. The product development process was structured and conducted according to the findings of the literature study. Broadly speaking, this involved identifying the project s value for the customer to correctly position the product development, identifying the feasible region wherein 845 different system concepts were generated and gradually narrowed to a single, final concept. The novel gripping mechanism was evaluated through CAE and performs within the requirements. Detailed design specifications are presented in the paper.

Based on experience from the case study, SBCE is discussed and observations and suggestions regarding the research gaps are presented. Design considerations for the continued development of the novel gripping mechanism are presented.