DAIKIN Industries Limited PRODUCT DEVELOPMENT OF ROOM AIR-CONDITIONERS USING SOLID EDGE Takashi MIYAWAKI [email protected] Daikin Industries Limited

DAIKIN Industries Limited

PRODUCT DEVELOPMENT OFROOM AIR-CONDITIONERS USING SOLID EDGE

Takashi MIYAWAKI

[email protected]

Daikin Industries Limited

Information Technology Advancement Center

October 14, 1999Solid Edge Second AnnualInternational User Group Conference


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


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


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


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)


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


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


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


Part


DesiredPart

ParallelApproach Sequential Approach

Insertion Insertion


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 :


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


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


Frame Part by FBM: Part Linkage with Assembly Layout

Generate parts by “Create In-place”, and Linking with Assemble Layout.


Frame Part by FBM: Correspondence to Design Modification

Shape modification before shelling


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


Example 2:Front Panel Parts - Parallel and Sequential approach -


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


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)



Designer

Divide Part into upper slit portion and rollet portion (when Patterning is included, other operations tend to becomes abnormally slow.)



Almost symmetric each other but have slight differenceapplied Family of Parts ( with Suppress Feature)

Right and Left covers


Front Panel Parts by FBM: Integration to one Part

Integrate into one part(FBM parallel approach)


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


Whole Image of the Product


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


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。

Documents

DAIKIN Industries Limited PRODUCT DEVELOPMENT OF ROOM AIR-CONDITIONERS USING SOLID EDGE Takashi MIYAWAKI [email protected] Daikin Industries Limited