Browsing by Author "Otto, Kevin"

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3D Scanning and computer-aided tolerance software analysis for product inspection
(2018-12-10) Fan, Xi
Insinööritieteiden korkeakoulu | Master's thesis
Tolerances are vital for every physical product, with a tight connection and competing needs between engineering design and manufacturing. 1D, 2D and 3D tolerance analysis can be applied to any product for determining these tolerances. With increase in dimensions the difficulty of tolerance analysis also increases. This research explores tolerance analysis in 3D situation. 3D scanning is a recently developed technology. In the industrial field, this technology is popular for inspecting product quality and in reverse engineering. It compares the dimensions between the 3D scanning model and the CAD model to inspect product quality. It also can generate a CAD model out of the 3D scanning model used in reverse engineering. The device mainly used in 3D scanning is the 3D optical scanner and the 3D laser scanner. These two types of 3D scanner use the same triangulation principle but one uses optical light and the other laser light. This research includes a 3D tolerance analysis and 3D scan. Before tolerance analysis a tolerance stack-up analysis was completed. Tolerance analysis was done using Crystal Ball software. The software uses Monte Carlo simulation to get results based on HTM calculator in Excel. HTM calculator contains every transformation nominal position and tolerance value. HTM calculated nominal position distance should be the same as CAD software Creo measured distance. Transformation nominal position was based on a loop diagram. Tolerance value was based on the defined tolerance in drawing and 3D scanning value. 3D scanning in this research is used to inspect product quality. Both parts and the assembly device were scanned. Parts were selected based on the loop diagram. The device was assembled using 3D scanning parts. The results of the tolerance analysis were shown through distribution charts and sensitivity charts. Comparing the simulation results of 3D scanning data and defined tolerances in drawing, distribution charts results were not reliable but sensitivity charts results were similar. The results of 3D scanning measurement data show the current device tolerance value is too tight. 3D scanning devices used in this research are not suited for large scale implementation, e.g. in product inspection.
Additively Manufactured 2D Matrix Code Direct Part-Marking Casting Requirements
(2023-10) Uyan, Tekin; Jalava, Kalle; Orkas, Juhani; Otto, Kevin
A1 Alkuperäisartikkeli tieteellisessä aikakauslehdessä
Direct part-markings (DPMs) can be formed into metal castings, using additively manufactured two-dimensional matrix encoded tags (AM2D) placed in a sand or shell mold. It has been unclear how thin a part can be and yet form a readable DPM. There must be sufficient molten metal to burn away the tag, and sufficient feeding pressure to form the 2D matrix code dot pattern. Here the formability limit for the casting of any AM2D (polymer) tag is shown to be the smallest heat energy from the latent heat of condensation needed to raise the temperature of the tag to ignition to burn the tag from the mold. The minimal part thickness that can be utilized is thereby derived. The minimum thickness is calculated to predict a part of various materials and compared positively with experiments. This provides a means to compute required part metal thickness to positively form a DPM tag before casting.
Advanced product quality planning implementation in a medium-size company
(2019-06-17) Hallikainen, Iisakki
Insinööritieteiden korkeakoulu | Master's thesis
Analysis of standby pump technology update and effect in gas driven firefighting systems
(2019-10-21) Simmelink, Karel
Insinööritieteiden korkeakoulu | Master's thesis
Analysis of user committed values in a product configurator
(2017-12-11) Seppänen, Sami
Insinööritieteiden korkeakoulu | Master's thesis
This thesis studies the commitments product configurator users are making when configuring products. Product configurators are tools supporting mass customization and help users to select correct products to quote for the customer based on customer requirements. Configuration is an activity based on assembling product modules together with the help of rules determining how the modules can be combined with each other. A commitment made in a configuration session is both the question that has been answered and the answer to that question. This thesis focuses on researching the questions that have been answered in configurations. The research was conducted by gathering data from a data warehouse of a Case Company, and making an analysis of the data to determine what has been chosen in the product configurator. The data was used for making an analysis about which features are committed in the product configurator and which products are the end results of configurations. The realized products were compared to the products chosen in the old sales system of the Case Company to see if the product offering differs from history when using the configurator. Furthermore, the configuration questions that had been committed together were analyzed using a statistical procedure called principal component analysis. Three different results were concluded in this study. The first result from the analysis about what is committed in the product configurator the most show regional and product series dependent differences in making commitments. The second result from the study tells that there is no clear indication that the product offering would differ significantly from history based on the gathered data. However, the number of quoted and ordered typecodes is decreasing compared to history. Finally, a number of fields that were committed together were identified using the principal component analysis. In addition, the fields that are not committed when some other fields are committed was also a part of the result.
Ball tester operation and measuring accuracy analysis
(2020-08-17) Fridman, Dani
Insinööritieteiden korkeakoulu | Master's thesis
Product development at Neles Finland Oy includes valve leakage testing in a laboratory. A ball tester can improve valve testing capabilities in a laboratory and increase efficiency by enabling testing focus on just the seat from a control valve. The goal of the thesis is to investigate and determine how leakage should be measured correctly as well as how the measuring accuracy of the ball tester can be determined. The ball tester was studied to break down its operating principles and various experimental tests were conducted to examine how leakage behaves. Tests were done where the pressure and leakage rate drop were monitored with a leak to plot how linearly they occur. Volume was also varied in the tests to investigate the significance of volume with pressure drop. Results show that the measuring accuracy of the ball tester can be determined by comparing experimental test data to the ball tester and comparing resulting leakage rates that can be achieved from both with the same pressure drop. It was also determined what the optimal way to measure leakage is with the ball tester which showed that leakage rate needs time to stabilize in the beginning of a leakage rate measuring test.
Centralized CAD-data management via platforms
(2021-05-17) Vartiainen, Pekka
Insinööritieteiden korkeakoulu | Master's thesis
Computer Aided Design (CAD) is a method to create 2D- or 3D-designs with the assistance of computers. CAD-data has become one of the key factors in modern era industry due to its higher efficiency compared to traditional drawing on paper. This thesis describes an optional way to control CAD-design data for companies which don’t use Product Data Management -software (PDM) for their CAD-data management. The absence of PDM can cause challenges with modular products if they use a product platform as the core of their design. The changes in items need to get updated into the platforms to have the products designed according to newest innovations. Central theory of product platforms and modularity is discussed to explain the relevant concepts related to the topic. Different ways of keeping the platform designs updated are tested and evaluated. Multiple different ways of creating and modifying the designs of items (from single parts to assemblies) in terms of storing the data are discussed. Various functionalities of PTC’s Creo are described to create a basis for the CAD-data management on the computers’ operating system. Creo is used for the case study since it’s being used as the CAD-software by the case study’s company. Possible risks relating to design data from both internal and external side are considered. A chosen method for controlling the design data is represented alongside with a possible data repository structure. Its capabilities and limitations are analyzed. The method is found to be applicable and help in possible implementation of a PDM-software. Possible future research relating to increased automation of the chosen method is suggested.
Computationally efficient model for energy demand prediction of electric city bus in varying operating conditions
(2019-02-15) Vepsäläinen, Jari; Otto, Kevin; Lajunen, Antti; Tammi, Kari
A1 Alkuperäisartikkeli tieteellisessä aikakauslehdessä
The uncertainty of operating conditions such as weather and payload cause variations in the energy demand of electric city buses. Uncertain variation in energy demand is a challenge in the design of charging systems and on-board energy storages. To predict the energy demand, a computationally efficient model is required for real-time applications. We present a novel approach to predict energy demand variation with a wide range of uncertain factors. A factor identification is carried out to recognize the range of variation in the operating conditions. A computationally efficient surrogate model is generated based on a previously developed numerical simulation model. The surrogate model is shown to be 10 000 times faster than the numerical model. The surrogate model output corresponds with the numerical model with less than 1% error. The energy demand of the surrogate model varied from 0.43 to 2.30 kWh/km, which is realistic in comparison to previous studies. Successful sensitivity analysis of the surrogate model revealed the most crucial factors. Uncertainty in temperature, rolling resistance and payload contributed most to the variation in energy demand. Variation in these factors should be taken into account when predicting energy consumption and while planning schedules for a bus network. (C) 2018 The Authors. Published by Elsevier Ltd.
Design of an engineer-to-order product configurator with CAD integration
(2020-05-18) Korhonen, Konsta
Insinööritieteiden korkeakoulu | Master's thesis
Companies that engineer products according to customer orders have increased the usage of mass customization methods in their delivery processes. Modern configurator software use design automation and knowledge-based engineering methods together with CAD and PLM system integration. This allows them to automate repetitive engineering tasks using generative models. The objective of the study was to research configurator technologies and methodologies and implement a CAD integrated configurator used in the order engineering process of a mediumly standardized modular engineer-to-order (ETO) prod-uct as a case study. The secondary objective was to measure the effectiveness of the configurator compared to previous configuration processes in the target organization of Konecranes Winch Platform. A literary review of configurator technologies and development methodologies was conducted in parallel with a case study of implementing a mechanical configurator for a new product series of a an ETO overhead crane hoist. The configurator generates a configured bill-of-materials, 3D models and drawings of the product variant based on output parameters from a sales configurator. Re-use of configured modules is implemented, with lim-ited revisioning capabilities. Design tools used were CAD system Siemens NX, PLM sys-tem Teamcenter and configurator software Rulestream. The result of the case study is a configurator that can produce the required output, with the limitation that the generated drawings often require manual finalization work. Recommended configurator development and maintenance principles are presented. The comparison of configuration times shows that the old configurator that assembles pre-made components with pre-made drawings is faster with standardized inputs, but this comes at the expense of increased variant maintenance work. Additionally, when non-standard input values are required, the new configurator has the edge, as it can configure the non-standard product variant essentially at the same speed as the standardized one. The major challenges in CAD integrated configurator development are still related to the implementation of the integration with CAD and PLM systems. Furthermore, products that are not fully assemble-to-order or ETO remain challenging, as configurator software are tailored to either, but do not fully support both at the same time.
Design prototyping methods: state of the art in strategies, techniques, and guidelines
(2017) Camburn, Bradley; Viswanathan, Vimal; Linsey, Julie; Anderson, David; Jensen, Daniel; Crawford, Richard; Otto, Kevin; Wood, Kristin
A1 Alkuperäisartikkeli tieteellisessä aikakauslehdessä
Prototyping is interwoven with nearly all product, service, and systems development efforts. A prototype is a pre-production representation of some aspect of a concept or final design. Prototyping often predetermines a large portion of resource deployment in development and influences design project success. This review surveys literature sources in engineering, management, design science, and architecture. The study is focused around design prototyping for early stage design. Insights are synthesized from critical review of the literature: key objectives of prototyping, critical review of major techniques, relationships between techniques, and a strategy matrix to connect objectives to techniques. The review is supported with exemplar prototypes provided from industrial design efforts. Techniques are roughly categorized into those that improve the outcomes of prototyping directly, and those that enable prototyping through lowering of cost and time. Compact descriptions of each technique provide a foundation to compare the potential benefits and drawbacks of each. The review concludes with a summary of key observations, highlighted opportunities in the research, and a vision of the future of prototyping. This review aims to provide a resource for designers as well as set a trajectory for continuing innovation in the scientific research of design prototyping.
Development of a low-cost hydrogen sulfide gas sensor for wastewater monitoring applications
(2021-03-15) Moy, Samuel
Insinööritieteiden korkeakoulu | Master's thesis
Monitoring hydrogen sulfide(H2S) gas in pump stations is an essential aspect of corrosion and odor management in wastewater networks. Monitoring H2S gas concentration allows wastewater utility companies to identify potential problems in wastewater networks, such as blockage of pumps, corrosion buildup, and hazardous environments. However, wastewater utilities do not have H2S gas sensors in most pump stations because there are many pump stations to monitor. The sensors have unnecessary features and thus expensive. This thesis develops a low-cost H2S gas sensor device for the wastewater network environment. This is accomplished by evaluating the feasibility of two electrochemical sensors technologies: the Winsen and SPEC sensor technologies. These technologies are tested in a pump station to determine their response time, accuracy and feasibility. The results show that utilizing the Winsen sensor technology with the UART method to yield continuous readings is feasible. Conversely, the results show that the SPEC sensor yields negative concentration values and does not react to changes in environment. The proposed sensor device comprises the Winsen sensor technology, a microcontroller, a real-time clock and a 5-volt power supply, which accomplishes a low material cost of approximately 35 USD. The Winsen sensor technology conforms to the specification established by the client company. Nevertheless, further development could lead to a more refined test method and an accurate calculation of sensor accuracy.
Development of modular architectures and support processes in product lifecycle management systems for design reuse
(2017-10-30) Nguyen, Minh
Insinööritieteiden korkeakoulu | Master's thesis
Differences between steel wire and synthetic rope reliability in hoisting applications
(2020-12-14) Stenman, Joona
Insinööritieteiden korkeakoulu | Master's thesis
The focus of this master’s thesis was researching rope failures in hoisting applications. In this thesis, the mechanics of steel wire rope and synthetic rope failure were researched, and the reasons for rope replacements made in the field were analysed. Synthetic rope is a rather new product in hoisting applications. Therefore, comprehensive field data was not available. By analysing steel wire rope failures in the field together with the effect of hoist frame sizes and usage profile on failure modes, the kind of failures that occur with synthetic rope were estimated. Identifying typical failure modes and their root causes ensures successful inspection of synthetic rope and, thus, safe usage. The target company’s maintenance data concerning steel wire rope failures in customer devices was utilized in this master’s thesis. This information was statistically analysed by identifying and categorizing occurred failure modes. Researched hoists were divided into three groups based on their model. In these model groups, hoists were categorized into smaller groups based on their frame size and capacity. The target company’s rope failure reports and authority accident reports were used to analyse the causes of rope failure. From service data it is seen that the major failure modes of steel wire ropes are rope deformations and broken wires. Deformations are typically caused by abnormal usage. Broken wires are caused by natural fatigue when the rope is bent over the sheaves during lifting movement. Based on field data, a trend is detected that deformations caused by abnormal usage are more common in workshop than process usage hoists, and their share increases when hoist frame size decreases. From rope failure reports, it is seen that the most significant causes are misuse or either failed or neglected inspection. Risks of synthetic rope failure and their occurrence were identified by failure mode, effects and criticality analysis. For the most essential found failure modes, root cause analysis was performed to identify and minimize factors causing damage. Internal wear of rope, broken rope by cut and decreased load bearing capacity caused by high temperatures are identified as the most critical failure modes for synthetic rope in the field. Research shall be continued by developing failure detection techniques for synthetic rope inspections, such as how to detect ropes exposed to high temperatures, UV radiation or shock loads. In the future, the target company’s field data should be developed so that more accurate analyses can be performed, and failure mode, effect and criticality analysis can be updated to correspond to real failure modes and their occurrence in the field.
Digital twins in a process engineering education environment
(2020-12-14) Virtanen, Maiju
Insinööritieteiden korkeakoulu | Master's thesis
Digital twins are growing more popular in the manufacturing industry and across disciplines. The term typically refers to a digital up-to-date representation of a physical system or entity. The use of real time data provided by sensors in the processes enables the user of processing equipment to react fast and accurately to issues that arise and to otherwise make well-informed decisions relevant to the process. The development in machine-to-operator communications is one of the key enablers of Digital Twins and is considered a core feature. This thesis focuses on establishing what a Digital Twin can be in a process related practical learning environment. Since Covid-19 pandemic has had an effect on working methods not only in industrial working environments but also in education and academia, the use of simulation and remote working practices are discussed. Different subcategories of Digital twins are discussed as well as their applicability to the chosen case of a Process Engineering Educational Environment of Arcada University of Applied Sciences. A user research is conducted as lead user interviews as well as surveys for two sets of stakeholders, the teaching staff and students. Based on these, the needs for the development case are identified and presented. Possible applications of digital twin technologies in the predetermined space are presented and their applicability is discussed. The actual implementation of the solutions is left outside the scope of this thesis.
The effects of mold cavity sensoring in injection molding production
(2019-12-16) Wickström, Jesse
Insinööritieteiden korkeakoulu | Master's thesis
The aim of this thesis is to study the potential of introducing cavity sensor technology for quality assurance in an injection molding-centered manufacturing environment. Applying sensor data for quality monitoring and control methods was investigated by measuring the thermodynamic events that take place inside the mold cavity during the injection molding cycle. Previous research in this field has proven that cavity pressure and temperature data is correlated to the quality of an injection molded part. The relationship between cavity sensor data and molded part quality was studied by retrofitting a production mold with cavity pressure and temperature sensors, and by collecting data from the set-up by conducting two designed experiments. The conclusions of this study were based on a combination of experimental results and a literature study. The experimental results indicate that the peak pressure in the mold cavity can be utilized to predict dimensions of the molded part, which can be applied for real-time process performance monitoring. Additionally, the results hint that cavity pressure and temperature data can be used for monitoring uncontrollable fluctuations in the process and mold optimization operations.
Ensuring crane reliability by utilizing the life cycle data of its digital twin
(2018-08-20) Anthoni, Jonas
Insinööritieteiden korkeakoulu | Master's thesis
Facing extreme uncertainty–how the onset of the COVID-19 pandemic influenced product development
(2023) Hölttä-Otto, Katja; Björklund, Tua; Klippert, Monika; Otto, Kevin; Krause, Dieter; Eckert, Claudia; Nespoli, Oscar; Albers, Albert
A1 Alkuperäisartikkeli tieteellisessä aikakauslehdessä
The COVID-19 pandemic has been a global disruption, but little is known about how it impacted product development. Based on interviews of 24 practicing product development leaders, we find that COVID-19 generated a unique combination of external and internal uncertainties and thus had several direct impacts on product development. Initial adaptations were reported in the level of innovation pursued, the development processes and the resourcing. In terms of level of innovation and resourcing, no uniformity in adaptations were observed: opposite changes were made across radical/incremental, expanding/reducing, local/international and internal/external collaboration balances in the different companies’ product development activities. Process adaptations were more uniform in direction, focusing on increasing flexibility and agility. In terms of product development methods for different phases, we find companies quickly seeking creative approaches to replace their traditional methods in idea generation, prototyping, customer interaction, validation etc. with virtual means. Furthermore, changes in human interaction quality, particularly informal interaction, were seen to have far-reaching, unintended negative consequences on their creative efforts, whether in product development, development process or resourcing. Overall, the results highlight the diversity of adaptive choices available to respond to external uncertainties, though more research is still needed on how these influence longer term resilience.
How to Use the Levers of Modularity Properly-Linking Modularization to Economic Targets
(2022-07-01) Schwede, Lea-Nadine; Greve, Erik; Krause, Dieter; Otto, Kevin; Moon, Seung Ki; Albers, Albert; Kirchner, Eckhard; Lachmayer, Roland; Bursac, Nikola; Inkermann, David; Rapp, Simon; Hausmann, Maximilian; Schneider, Jannik
A1 Alkuperäisartikkeli tieteellisessä aikakauslehdessä
Product developers are faced with the challenge of covering an ever-increasing external variety with as little internal variety as possible. Modular product architectures offer one way of resolving the challenge. They have an impact on all life phases and on economic targets. These effects are represented in the Impact Model of Modular Product Families. A large number of modularization methods can be found in the literature. The modularization methods consist of different activities: decomposition of product, analysis and revision of components, and reintegration to modules. Module drivers play a major role in reintegration, as they determine which components together form a module. It is not yet clear what effects different modularization methods involving different module drivers have on economic targets. For this reason, the module drivers are examined in their role as levers of modularity and integrated into the Impact Model via access points. By documenting the results in a specially developed uniform method step description and the Impact Model, we enable the selection of modularization methods with regard to their economic impact. The introduction is followed by the state of research. In Sec. 3, the research problem and the research approach are presented. In Sec. 4, the generic method step description is applied to seven modularization methods. Based thereon, the modularization methods are compared with each other with regard to their addressed economic objectives. In an explanatory example, the method selection made possible by this is presented. Finally, the results are discussed and an outlook is given.
Identifying and assessing the most relevant variables affecting vibration response at variable-frequency drives
(2020-06-15) Hartikainen, Pyry
Insinööritieteiden korkeakoulu | Master's thesis
Electrical motors can be found at various locations with varying environments as the world is becoming increasingly electrified. Electrical motors are often accompanied by variable-frequency drives (VFDs). Hence, VFDs can nowadays be located at environments differing greatly from clean electrical rooms where they could be typically found in the past. Even when the environments are changing, the typical basic structural design has been inherently unaltered. VFDs with similar structure can be used at various environments containing multiple different variables affecting to the expected operating lifetime. One significant environmental variable is vibration, which poses risk for especially fatigue damage. The work presented in this thesis addresses the capabilities of current basic structure of a typical cabinet-VFD. Important variables affecting vibration response at VFD-structure are searched for. A computer experiment model is created for these variables for assessing the response generated by variance within values of variables. Eigenfrequency analyses are concluded with Abaqus for typical structure of cabinet-VFD with the experimental values for acquiring raw data. Raw data acquired from eigenfrequency analyses is further analyzed concentrating for most important natural modes in various directions. Responses of mode number, mode frequency, effective mass and relative effective mass are assessed regarding the most important natural modes. Models for most important directions proved to be very accurate, hence being especially useful for assessing the current design. The results indicated that the mode shape of most important natural mode cannot be altered with current design in regard to most important directions. However, mode shape could be altered for less significant directions. More importantly, natural frequencies of most important natural modes could be effectively altered with varying variable values for all directions. Absolute and relative effective masses proved to be modifiable as well.
Impact of part traceability on quality
(2019-12-16) Koskimaa, Markus
Insinööritieteiden korkeakoulu | Master's thesis