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DAIKIN Industries Limited PRODUCT DEVELOPMENT OF ROOM AIR-CONDITIONERS USING SOLID EDGE Takashi MIYAWAKI Daikin Industries Limited.

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Presentation on theme: "DAIKIN Industries Limited PRODUCT DEVELOPMENT OF ROOM AIR-CONDITIONERS USING SOLID EDGE Takashi MIYAWAKI Daikin Industries Limited."— Presentation transcript:

1 DAIKIN Industries Limited PRODUCT DEVELOPMENT OF ROOM AIR-CONDITIONERS USING SOLID EDGE Takashi MIYAWAKI Daikin Industries Limited Information Technology Advancement Center October 14, 1999 Solid Edge Second Annual International User Group Conference

2 DAIKIN Industries Limited Overview of DAIKIN Air-conditioners for Store and Building Room Air-conditioners Company Profile Number of Employees : About 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 Example of Air-conditioners

3 DAIKIN Industries Limited History of Three Dimensional CAD Advancement in DAIKIN and Purpose of This Trial Project l First Step : Introduction Term (Up to the present) –In order to apply three dimensional CAD to Air-conditioners piping design, system development using Pro/E was started from –Trial use and improvement of the system until –Release to user from 1995, and now it is used in the almost of main developments of air-conditioners outdoor units. l 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 »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 Verification of Solid Edge Function by Practical use in the product development Purpose of This Trial Project

4 DAIKIN Industries Limited Details of Verification l Function verification –Function of 3D design for Air-conditioners –Performance speed –Reliability l Utility Verification –Decrease of learning time than the system before –3D design of large and complex plastic parts in the real development l 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

5 DAIKIN Industries Limited Overview of Solid Edge Trial Project - Application to Product Development of Room Air-conditioners - l 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 l 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)

6 DAIKIN Industries Limited Theme in Applying 3-D Design l Effective modeling of Large and Complex plastic parts –Characteristics of Feature base modeler »Advantage : Make the design efficient, Information Transmission of design Intent l Effective Approach in Series Design and Appropriation Design l Transmit design intent correctly l Avoid stupid mistake »Problem : Handling of Large Part Features l 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

7 DAIKIN Industries Limited About Function Based Modeling l Modeling by functional character rather than geometric l 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 l 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

8 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 AssemblyLayout Control of Shape Feature Function Part Function Part Function Part Assembly Feature Desired Part Insertion for Integration Part Feature Part Feature Part Feature Desired Part Parallel Approach Sequential Approach Insertion

9 DAIKIN Industries Limited Implementation Result 1 : Concept Design by Solid Edge Data Transfer by 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 one and It is difficult to design by 2D Existing product Concept Design by Solid Edge Result in Concept Design Function : Utility : Effectiveness : Function : Utility : Effectiveness :

10 DAIKIN Industries Limited Implementation Result 2 : Detail Design by Solid Edge Heat Exchanger Assembly Fan Assembly Frame Assembly Electric Component Assembly Air clean unit Air 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 of front panel

11 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 by assembly insert

12 DAIKIN Industries Limited Frame Part by FBM: Part Linkage with Assembly Layout Generate parts by Create In-place, and Linking with Assemble Layout.

13 DAIKIN Industries Limited Frame Part by FBM: Correspondence to Design Modification Shape modification before shelling

14 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

15 DAIKIN Industries Limited Example 2:Front Panel Parts - Parallel and Sequential approach -

16 DAIKIN Industries Limited Front Panel Parts by FBM: Industrial Design Surface l Industrial Designer Modeled the right half of outside shape of Front Panel Integrate them by insertion to a part, and divide the part into two parts using Divide by face Generate the other side by Insert Part and Mirroring Completion of Panel Face

17 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)

18 DAIKIN Industries Limited Front Panel Parts by FBM: Detail Modeling 2 l Designer Divide Part into upper slit portion and rollet portion (when Patterning is included, other operations tend to becomes abnormally slow.)

19 DAIKIN Industries Limited Front Panel Parts by FBM: Detail Modeling 3 Almost symmetric each other but have slight difference applied Family of Parts ( with Suppress Feature) Right and Left covers

20 DAIKIN Industries Limited Front Panel Parts by FBM: Integration to one Part Integrate into one part (FBM parallel approach)

21 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 the Screen Not coordinate here Avoid mistake which will occur in case of two dimensional design

22 DAIKIN Industries Limited Whole Image of the Product

23 DAIKIN Industries Limited Result of Direct and Rapid Prototype from 3D Model l 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 l 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 DrawingDesign Design Inquire Inquires Decrease Modification of mistake Alternation Prototype making Accuracy Improvement Comparison between 2D and 3D about Front Panel Parts Prototype making

24 DAIKIN Industries Limited l l David Hagood


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