The aim of this thesis is to perform an optimization of the assembly tool set for Dellner's DAC Draft gear, which are used when compressing the Elastomer spring stack. By performing and following the results of a DFA analysis, using The Boothroyd and Dewhurst method, thereby identifying the most time-consuming operations, eliminating unnecessary separate parts, and then re-constructing the tool set. The new alternative solutions have been modeled as 3D-Cad geometries that have then been FEM analyzed and corrected until they meet the set requirements. The work ends with a new DFA analysis of the workflow in the implementation of the new tools. To help with the development, a test assembly with the current production manner has been carried out and evaluated. The result of this thesis shows that by identifying time-consuming steps in the use of the assembly tools, it is possible to save time when assembling the given product, even if the product itself remains in unredeemed condition.
As a second step in the report, a Heavy-Duty pressing tool with associated support has been designed, to be able to eliminate an otherwise standalone step in the assembly, Full functional stroke. Integrating this step directly into the assembly will further reduce the assembly time and is therefore in great demand from Dellner.
Some of the ideas that pervade the work with the development of new tools are taken from Poka-yoke, the production should be fail-proofed with the help of the new tools, in addition, the current need for two collaborating technicians has been constructed away through the design of the updated tool set.
The conclusion of the work carried out within the framework of this thesis is that with the developed tool set, Dellner will be able to save both time and reduce personnel costs during the assembly of Draft gear.
2023.