Thermoplastic frame tooling:
- Definition of part and process specification by concurrent engineering to understand the specimen architecture and the available design level as well process quality requirements.
- Preliminary tooling design comprising the design (mechanical, thermal, automation), the justification, the manufacturing and the quality control of the Tooling Set within the adjoining elements. Moreover, auxiliary device or equipments have been identified at this stage.
- Main tooling design and validation including matured 3D models and 2D drawings with the operational assessment. Key Tolerances and specification have been defined at this stage and a mock up mould and auxiliary components have been manufactured for preliminary experimental testing. In parallel, the thermal control system have been determined as well as the automatic control system architecture which aims to deal with high production rate scenarios.
- Manufacturing of the tooling and set-up of the thermal control system and logic process. Previous testing results has been considered to adjust the design and process workflow as required.
- Manufacturing of the parts comprising the closing frame. Process optimization driven by iterative testing, quality evaluation and process output enhancement.
- Delivery of the parts and assembly aided by tooling set.
Assembly tooling set:
- Plateau phase-Concurrent Engineering where the specimen architecture and the available design level in order to outline tool options and best assembly sequence/philosophy has been established. Within this task all the information regarding geometry, constraints, preliminary assembly philosophy and related key characteristics, as well as tools for the handling, assemblies and transportation for the built assembly and adjoining elements integration. During these tasks, innovative solutions for tooling related to the sensorization of the assembly tooling, the automation of parts positioning and ALM techniques have been technologically screened and discussed.
- Concurrent engineering with the Topic Manager to reach the Preliminary Design Review (PDR) level of the Tooling Set. Within this task, the inputs of the design, the justification, the manufacturing and the quality control of the Tooling Set within the adjoining elements have been defined as a basis fur topling devlopment. The outcome of this task have included preliminary 3D models including the former design of measuring and monitoring systems.
- Main tooling design, validation and development of measuring tools. A Failure Mode and Effect Analysis (FMEA) analysis has been carried out to foresee and prevent any risk for the project, proposing an appropriate mitigation plan. Moreover, FEM analysis including the weight of the components and assembly loads created through the process has been conducted bringing the PDR design to CDR maturity level. In parallel, the measuring and sensing solutions have been selected and developed (in simulation, by experimental testing) driven by assembly process specifications.
- Manufacturing and geoemtrical validation of the tooling set
- Set-up (mechanical, electrical, control) and preliminary testing of the developed technologies (force sensors, vision, metrology assistant, automatic drives, HMI) integrated in the automatic assembly machine. Pre-Ship acceptance test in TEKNIKER premises.
- Delivery of the tooling set to Topic manager facility.
- Installation and set-up in shopfloor conditions. Testing of technologies through the assembly process.
- Assembly of ARE product driven by the tooling set and advanced smart solutions.
Based on both tooling set, the different components have been manufactured and the ARE product has been assembled and measured. Moroever, developed technologies have been tested and process performance has been studied for further improvement.
