Home

Concept development of field analysis equipment for mining and

1. Ll ad AR AA a KE EE A el S IAA SE Concept development of field analysis equipment for mining and exploration application Master s thesis in the Master Degree Programme Product Development VASUPOL KUNAVUTI Department of Product and Production Development Division of Product Development CHALMERS UNIVERSITY OF TECHNOLOGY Goteborg Sweden 2012 Concept development of field analysis equipment for mining and exploration application Master s thesis in the Master Degree Programme Product Development VASUPOL KUNAVUTI Department of Product and Production Development CHALMERS UNIVERSITY OF TECHNOLOGY Goteborg Sweden 2012 Concept development of field analysis equipment for mining and exploration application Master s thesis in the Master Degree Programme Product Development VASUPOL KUNAVUTI O VASUPOL KUNAVUTI 2012 Department of Product and Production Development Chalmers University of Technology SE 412 96 Goteborg Sweden Telephone 46 0 31 772 1000 Goteborg Sweden 2012 Preface This report is part of the thesis of the Master program Product development at Chalmers University of Technology in Gothenburg The thesis has been formulated over six months from September 2011 to April 2012 My advisor and examiner has been Professor Hans L Johannesson During the formulation of this thesis
2. Development phase begin with forming requirement s specification and identifying function and problem The problem function relation was made to show interference between the functions and to find the most effect and effected function Then generate the concepts and narrow its down by using evaluation method such as Pugh or Kesselring matrix and select the final concept The final concept will be present to the geologist and worker in mining field in order to capture their perception and perspective about the equipment The interview and other data collection method will be used Refinement and deliverables phase the final concept will be refined and finalized After that the CAD model will be created by using Autodesk inventor program Finally finish the report and presentation Appendix A Planning report 39 Time schedule The thesis is start in September 2011 and will end in March 2012 Task Name Start Finish EE EE Tee Tee pp maa j o t a a enema E A IC mm kass RE IN O mame mmm ow IN kass MEA z P besen Lenz me CN AN AAA ama O crei MECO ETICO ICI A Ir MECO ETICA CI A SS DER MECO ICI AECI EC INN IN METI CI lt EII EEN IEC III IN OO A ECO ME a zhbeeg Less IEEE sl BS ECOS MEE men a IO ee COS NEO EI CI O O O 40 Appendix A Planning report Deliverables The following are the lists of deliverables in each phase and desirable outcome of the thesis Phase 1 Sep 20 Nov 7 e List of requirements
3. 3 3 Concept table The use of the concept table see Table 3 1 was developed for this specific thesis The concept table was used for two purposes to collect the overall solutions in one table and to show the promising solutions that were evaluated from various methods The alternative solutions were indicated by color code The different colors mean that the solutions were excluded by different evaluation methods The total amounts of possible solutions are massive and the functions of the developed product have unique characteristic some can affect the complexity of the overall system and some have individual properties which can be influenced from other functions To simplify the process the sub solutions have been evaluated and selected from each function before starting to combine the solution The potential performance of a solution combination was synthesized to support the decision Table 3 1 Concept table Sub system o FA Sd S22 s13 Sim o 2d 52 2 23 S2m P S81 83 2 33 S3m_ apro peo ip En Sm1 Sn2 sng Sanm 3 4 Concept Evaluation Concept evaluation is the process of evaluating and selecting the potential concepts from the idea generation stage The aim is to narrow down the amount of concepts and decide which concepts have the highest possibility for becoming an actual product The concept evaluation methods were used in the thesis including the Elimination matrix the evaluatio
4. Detection 9 10 Fault will be passed to customer undetected
5. amp Blessing L 2007 Engineering Design A Systematic Approach Springer Tague N R 2005 The quality toolbox American Society for Quality Tomas From S 2011 Swedish Mining 2011 Nordic Steel amp Mining Review 195 7 11 6 11 Ullman D G 1944 The Mechanical Design Process PA McGraw Hill Ulrich K T amp Eppinger S D 2008 Product Design and Development Singapore Mc Graw Hill Appendix A Planning report 37 Appendix A Planning report Background Companies within the mining industry perform exploration drilling in order to find new mineral resources Currently this process is associated with high investments and high risks mainly due to the extensive cost and time it takes to perform the analysis of the rock samples The first prototype was produce based on the concept from product development The company decided to produce only a single core scanner to reduce the complexity of the prototype The next prototype will improve the design and function of the first prototype and will be produce in the future based on the final concepts of the thesis Purpose The aim of the thesis is to generate feasible concepts of X ray equipment based on the first prototype for performing field analysis of rock samples in mining and exploration applications The new product will be capable of analyzing multiple samples in a standard core box Objective The objective is to develop and redesign the current prototyp
6. Maintenance e Cleaning control air flow and air filter e Subsystem maintenance separate partitions and cabinet Environment e Environment heater fan and dehumidifier and temperature and humidity controller Layout e System layout The selected solution shown in the concept table Safety e Warning light position four one on each corner e Alarm system emergency stop and status light e Security key lock magnetic lock door sensor and key to start the machine Cover e Front hatch swing door opening down Next is a brief description of the outcome concept Figure 4 8 illustrates the integrated concept The core box loads into the instrument in the front side based on the solution called video player The user puts the core box on the loading tray which is then pushed into the machine The tray will slide to the start position then the instrument will start scanning The X ray components are attached to the actuator that moves from the left side to the right side of the machine When one slot is finished scanned the core box moves inward to start the analysis of the next slot The analyzing process continues until the last slot The number of slots varies depending on the dimensions of the core box and the size of the sample For the standard core box 1042 mm x 378 mm x 50 mm which is the ideal dimensions for the developed machine the number of slots per box is six or eight with the length of each slot being one meter 22 Chapter 4
7. received valuable assistance and information that has been critical in the successful completion of it would like to take this opportunity to thank all the people who have contributed in the different aspects of this thesis Special thanks must be given to Mikael Arthursson and Annelie Blomdahl supervisors and mentors at the company Niklas Arthursson product designer at the company and Efrain Calderon development engineer at the company Also thanks to Hans L Johannesson advisor and examiner at Chalmers University of Technology who guided me throughout the entire process Vasupol Kunavuti Concept development of field analysis equipment for mining and exploration application Master s thesis in the Master Degree Programme Product Development VASUPOL KUNAVUTI Department of Product and Production Development Chalmers University of Technology Abstract The problems with the exploration process within the mining industry are high investment and high risks because it takes a very long time and a lot of money to perform the analysis of the rock sample With the developed equipment the process will be shortened thus benefitting the mining and exploration companies who are the potential customers The aim of this thesis is to create a feasible and production ready concept of equipment for performing field analysis of rock samples in mining and exploration application During the course of this thesis work a product development
8. solutions that are not possible to produce The decision is based on the fulfillment of the criteria According to Pahl Wallace and Blessing the selection criteria consist of Criterion A The solution proposals are compatible with the overall task and with one another Criterion B The solution proposals fulfill the demands of the requirements list Criterion C The solution proposals are realizable in respect of performance and layout Criterion D The solution proposals are expected to be within permissible cost Criterion E Compatible with safety standards and introduce favorable ergonomic conditions Chapter 4 Concept development 19 The solution will be eliminated when it fails to fulfill one of the criteria For example as mentioned before the possible solutions of the feeding direction were narrowed down to one solution which is Y axis because the other solution X axis fails to fulfill criteria C unrealizable in principle In Table 4 3 the Elimination matrix shows the various methods of loading and unloading the core box However some solutions were eliminated because they do not fulfill all the criteria For some solutions more information is needed before a decision can be made The outcomes of the elimination matrices were carried on to the Kesselring matrix The full version of the Elimination matrix can be found in Appendix F Table 4 3 Elimination matrix of methods of loading and unloading core box Selection Criteria
9. Concept development Figure 4 8 Outcome concept The outer design consists of the front hatch feeding hatch and the touch screen for human machine interaction The front sides of the instrument are protected by the roll up door The edge and the corners of the machine are mounted with bumpers to absorb any impact that might happen during transportation With this container concept solution the instrument can be placed steadily inside the vehicle For the maintenance the tray is a good solution to prevent dust and dirt from the samples getting inside the machine The airflow control and air filter help collect the dust and purify the air inside the machine Because the instrument will be located near drill sites it is possible that the ambient temperature would be extremely low for example 40 degrees as in the case of the mine in Kiruna in the north of Sweden In order to ensure that the instrument is operating in this temperature the temperature controller is a good solution The heater can increase the temperature inside the instrument until it reaches the operating temperature The dehumidifier can be used to adjust the air humidity The layout of the machine was designed with the aim to make it as compact as possible but still fit all the sub systems including the X ray components electronic storage cabinet cooling system high voltage generator and computer cabinet The designed layout also accommodates the movement of the X ray com
10. Remarks Decision A E Ee ee 3 Video player petete 4 The oven 5 Sledge 6 Drawer 4 5 2 Evaluation based on Go No Go screening The other method that was used to exclude ideas that were not suitable for the machine was to evaluate them by the fulfillment of the selection criteria defined by the stakeholders Although some ideas fulfilled the criteria of the Elimination matrices they were not preferred by the company or were simply not feasible at the time From the discussions between the stakeholders the ideal solutions were sought The advantage of this method is that it generates discussion between stakeholders from which new criteria were recognized and discussed This method is also very flexible and easy to apply The functions that were evaluated using this method were transport solution system layout and safety For example for the system layout two possible solutions were proposed with the difference in the position of the cabinet cooling system and high voltage generator Both solutions have their own strengths and weaknesses After considering the criteria of maintenance the stakeholders made their decision The other examples are safety functions One of the requirements states that the instrument should have warning lights that can be seen 360 degrees around the machine There were two possible solutions either place one warning light on top of the machine or put a light on each corner of the machine The advantage of
11. X ray components while the machine is in operation The main reason why the machine has the hatches separately is to reduce the interference from the ambient environment as much as possible Because the feeding hatch will be opened more frequently for loading and unloading the core box compared to the front hatch that is opened only for maintenance of the components inside the analysis cage The size of the feeding hatch is very small only slightly bigger than the core box After the outcome concept was concluded the Failure mode and effects analysis FMEA was conducted in order to identify potential causes of failure The results of the FMEA show that the components that have the highest risk priority number are the cooling system which may not have enough water lead to the overheat of the X ray tube and the PLC system which risk of loose wires lead to a failure to control other system The result of this method was used as a design aid in the next stage of refinement and final design Table 4 5 shows the example of FMEA worksheet The complete version will be shown in Appendix H Table 4 5 The example of FMEA worksheet Potential 2 Risk priorit Item Potential Severity f Occurrence Detection p y E f Effects of Potential Cause s Current controls number Function Failure mode E S O Failure RPN Overloaded Short circuit No electricity Stop working Slow e movement Poor design Overuse the machine Poor design Overuse the machin
12. a single top positioned light is the number of light bulbs needed and the easy and straight forward design On the other hand a possible problem is the possibility that the machine might be installed on a table or some other high up position so that the user is unable to see the light With the corner positioned solution the advantage is that the lights are integrated into the frame and are easy to see by the user The drawbacks are that it is more expensive and the design is more complex After the discussions the stakeholders opted for the corner 20 Chapter 4 Concept development positioned lights because it passed the safety criterion which is more serious than the cost criteria The alarm warning function was excluded during this process Even though the purpose of this function is good it was not essential for the first development of the instrument 4 5 3 Kesselring matrix The Kesselring matrices introduced in chapter 3 4 3 were applied after the Go No Go screening The result from this process will be integrated as the outcome concept The process of selection begins with the meeting with the company s representatives to deal with the specifications requirements The problem is that all the requirements need to be prioritized By rating each requirement this can help solve the selection process A rating was given to each requirement depending on the importance of the requirement Hence 5 very important 4 between medium an
13. generated with respect to the Swedish Radiation Safety Authorities rules Finally the outer design was proposed by the product designer The final design of the developed instrument includes profile structure inner cage sub system cabinet analysis equipment feeding components front hatch feeding hatch and outer plate The prototype was created by a computer aided design program called Autodesk inventor The CAD model of the instrument was presented to the manufacturing workshop to ensure that the design is possible to produce For the sub systems consultation and advice was sought from an expert in the specific area 36 Chapter 10 References 10 References Beckhoff B Kanngiefser B Langhoff N Wedell R amp Wolff H 2006 Handbook of Practical X Ray Fluorescence Analysis Berlin Springer Bragsjo N Halonen M Johansson C Krpo V Sernevi C Smajic A 2010 Development and design of mobile and automatic drill core analysis machine Gothenburg Chalmers University of Technology Charantimath P M 2009 Total Quality Management Delhi Pearson Education India Masters Programme in Product Development 2010 Integrated Product Development Gothenburg Moss M A 1996 Applying TQM to Product Design and Development New York Narcel Dekker INC Otto K amp Wood K 2001 Product Design Techniques in Reverse Engineering and New Product Development Prentice Hall Pahl G Wallace K
14. of different functions in one place in order to get the complete idea of the overall process Due to the sensitivity of some of the solutions and functions the alternative solutions were evaluated one by one An example of the concept table is shown in Table 4 2 and the complete version can be seen in Appendix E The simple way to evaluate these solutions is to select the best solution for each aspect instead of evaluating a random combination of solutions because some aspect can affect the complexity of the entire system The result from the evaluation is shown in different colors The colors indicate type of method that used to exclude the alternative solutions Table 4 2 Extract from the concept table 4 PR A Ve LEET PA DEA Seer E 1 Loading ana unloading the core box 1 1 Direction 1 2 Method Rotation Sledge Drawer S ppi Sg ps Excluded by Elimination matrix Excluded by Kesselring matrix Excluded by Evaluation based on Go No Go 4 Selected concepts The evaluation of the solutions was conducted in three stages Firstly the Elimination matrices were used to exclude clearly disqualified solutions Secondly concept screening was performed by using the evaluations based on the Go No Go approach Finally concept scoring was conducted by using the Kesselring matrices as an evaluation and final selection tool 4 5 1 Elimination matrix The Elimination matrix is a preliminary screening method used to exclude the concept
15. process has been used This process involves identifying requirements specifications functional analysis concept generation concept evaluation and concept refinement The new product is a newly developed instrument that was improved from the first prototype Mainly the new feature of the machine is that it can scan multiple samples in a standard core box The design emphasis of the instrument was on operability usability safety transportability environment and compact ability The aim of the final design was to arrange the components in order to save space and weight while maintaining the functionality and quality of the analysis The three dimensional CAD model prototype was created by using a computer aided design program The design was based on the final concept The special focuses have been on the new feature of the instrument such as the loading and unloading of the core box It is important that the final design is feasible for production as the aim is to turn the concept into a fully functioning product The result of the thesis provides the solutions that analyses multiple samples in a standard core box The instrument can withstand the rough and tough environment and the exploration process can be performed faster and more accurately Keywords Mining Exploration rock analysis core sample core box Contents Met EE i AE d Te a aeau senate baea a tasantameeenteaiauitaooeeeaiagias ji A rodu COLON N 1 aM CT gelt EE 1 LS PUDO ee
16. specifications functional analysis concept generation of the different functions evaluation and outcome concept 4 1 The existing prototype The instrument s project stemmed from the product development project The purpose of the project was To help the company realize their vision of rationalizing the prospecting process and to design a concept for a basis for further development Bragsj Halonen Johansson Krpo Sernevi Smajic 2010 The project includes market analysis that was conducted around four main areas politics economics and social issues technology in prospecting possible market segments and competitors and their solutions The final concept of the project was called Mobile Automated Drill Core Analytical Technique MADCAT which combined the concepts of different sub functions namely chassis user interface analyzing core handling environmental protection and positioning of components Bragsj Halonen Johansson Krpo Sernevi Smajic 2010 The company decided to produce a single core scanner instead of a core box scanner to reduce complexity of the system The final concept of the development project differs from the prototype in the following aspects the number of input samples sub system and components because at that time the development team hadn t gained the knowledge about the components and sub systems yet and there existed a lot of unclear information and uncertainty Furthermore the techno
17. sub system parts and the side wall to make partition within the cabinet A concern was raised during the CAD modeling that because the electronic storage cabinet door opens very wide the cabinet will take a lot of space at the back of the instrument The best solution was to have two smaller cabinet doors The computer cabinet is placed on the front side The touch screen fastens onto the front plate and the cabinet door opens from the side of the machine Figure 6 3 displays a rendering of the sub system cabinets Figure 6 3 Sub system cabinets Chapter 6 Result 29 6 1 4 Analysis equipment The analysis equipment moves together in a left and right direction when the equipment scans the sample Because the X ray equipment is very fragile and valuable extreme caution must be taken to prevent the X ray equipment from colliding with other components The main concern about the equipment bracket was the positioning The flexibility to adjust the position is very important because it might happen that the user needs to adjust one of the components in order to get the most effective results The brackets were designed to have slotted holes to allow for easy extensive adjustments Figure 6 4 shows a rendering of the equipment bracket with slotted holes Figure 6 4 Equipment bracket 6 1 5 Feeding components The main function of the feeding components is to load and unload the core box As mentioned in chapter 4 4 1 the movement of the core
18. the electrical components that will be installed in the cabinet was made during the developmental process But it could not be completed because the number of components could not be identified at that time The sketch was based on the estimation of the number of components Further action should be to identify the components and design the electronic control system by using the sketch as a guideline Safety from radiation is the most important issue The recommendation is that the machine should be tested and measured for possible radiation leakage using a reliable method The result should not exceed the limitations in the SSMFS 2008 25 Swedish Radiation Safety Authorities rules and general advice regarding radiography and SSMFS 2008 40 Swedish Radiation Safety Authorities rules regarding usage of industrial equipment that contain closed radiation sources and X ray tubes For further development the instrument should be able to scan difference sizes of the core boxes The study indicates that there are differences in the standard core box in various countries For instance the specification on the standards that are used in Sweden Norway and Denmark are Sweden 455 mm wide x 1050 mm long Norway 343 mm wide x 1100 mm long Denmark 400 mm wide x 1050 mm long The trend is that the core boxes are getting narrower because of the weight issue The developed instrument has the ability to analyze a core box of length 1050 mm For the next model
19. the instrument should be able to analyze a core box 1100 mm long Chapter 9 Conclusion 35 9 Conclusion The purpose of the thesis was to generate a production ready concept of an X ray instrument for analysis of rock samples for field use The thesis has fulfilled its purpose It has improved the function of the existing prototype by making it faster and easier for the user to scan core samples The final concept includes the solution of a loading and unloading the core box the movement of the X ray equipment transport solution maintenance control environment layout safety and outer design Product development methods and tools have been used during the thesis work The Function analysis including the Process flow model and the Function means tree the Concept table Concept evaluation the Elimination matrix the evaluation based on Go No Go screening and the Kesselring matrix the Failure mode and effects analysis and Prototyping were intensively applied and greatly contributed to the success of this thesis In conclusion the developed instrument can analyze multiple samples in a standard core box It is possible to easily transport the machine to the mine or exploration site Regarding the maintenance the machine was designed to ensure that the users can maintain the equipment easily lt can withstand the rough and tough environment The layout of the machine was designed to be as compact as possible Regarding safety the concept was
20. tree Analyze rock samples Handle the core box Handle the X ray component Feeding system X ray system Load and unload core box Detect core box Move core box Unload core box Move X ray components Analyze sample Linear actuator Sensor Sample Motor Feeding system X ray Motor X ray detector Appendix D Relations diagram 49 Appendix D Relations diagram Loading amp Inside Temp Rise Unloading Sample Drop Maintenance Movement of X ray Components Layout tube amp Core box Design Cover part Transport solution 50 Appendix E Concept table Appendix E Concept table 1 1 Direction 1 2 Method Rotation zr Ke 2 1 X ray components movement 3 X ray components move ae axis incas move Z axis Up Zaxis Up down down Core box Core box move X axis move X axis left left right right Y axis In out Nothing 3 1 Edge Protection Appendix E Concept table 51 3 2 Window common panel protection 3 3 Holding Securing in vehicle 3 4 Handle 4 1 Cleaning Clean room Vertical EE d SE w i EI e f 5 is D 4 2 Sub system maintenance 5 1 Control Environment 52 Appendix E Concept table 6 1 System layout 7 1 Warning light position 7 2 Alarm system 7 3 Security 8 1 Front hatch Exclude by Elimination matrix geen by baso Exclude by Selected concepts valuation base Kesselrin
21. value Weighted Value Weighted Value Wo Value v3 Value Va Value ES W V2 W V3 W V2 ALIAS Ergonomic Safety al a oss 2 o ol 3 omg Reliability os s os al os gt os a os psestheticdesign 1 008 _4 0321 3 oz 34 oz 4 o32 Maintenance 2 Control Environment 0 11 0 42 0 21 0 21 A 0 42 TN Production a A E MEE ME E cot onf 042 af nai 3 032 4 oa Total 100 lp so 250o 384 Chapter 4 Concept development 21 4 6 Outcome concept The result from the evaluation methods is the outcome concept that integrates each function solutions into one concept The concept table See Table 4 2 was used to present the selected solutions and also the other alternative solutions which were excluded by the Elimination matrices the evaluations based on Go No Go screening and the Kesselring matrices The list below is the selected solutions for the different functions The concept table can be viewed in Appendix E Loading and Unloading core box e Direction Y axis e Method Video player Movement e X ray components movement X ray components move X axis left right Z axis Up down Core box move Y axis In out Transport solution e Edge Protection corner bumpers and edge bumpers Glass window common panel protection roll up door cover on one side Holding Securing in vehicle container solution corner hole forklift pockets e Handling container solution corner hole forklift pockets
22. User injury Manual Maintenance list ESA Appendix H FMEA worksheet 61 ae Poor design Overuse the Overloaded Short circuit 4 gny Regularly check the system machine 56 Poor design Overuse the Motor aa No No electricity Stop Stop working Low Low voltage power supply failed power supply failed Maintenance list EO eae esa Linear actuator No electricity Stop working sa Low voltage power supply failed Maintenance list ao Cooling system PLC Does not stop the machine Damage to human or machine MEM Safety PLC error e Regularly check the system Emergency Stop User does not notice the ly check th Delay of light turning on SC Seen lees PLC error Light failed MO Regularly check the system ES Status light Broken light bulb Broken light bulb bulb No status Nostatusiight Crush with other components with other Crush with other components Maintenance list Maintenance list gt circuit verse t Regularly check the system the system Unexpected restart Wasting time Computer failed error EE Maintenance list Computer Unexpected shut down Machine stop working NE Computer failed error Maintenance list 62 Appendix H FMEA worksheet Delay of light turning on Wasting time a PLC error Light failed E Regularly check the system MEN LED Lamp Broken light bulb Cannot take pictures Crush with other components ME Maintenance list MES No electricity Cannot lock the door NN High voltage p
23. a design aide A failure can be a mechanical failure based on any chance that the component assembly or system fails to perform its intended function Table 3 4 illustrates the FMEA worksheet It contains four indicators Potential failure Potential effects of failure Potential cause and Current controls Also there are three ratings Severity Occurrence and Detection Otto amp Wood 2001 Severity relates to the seriousness of a potential effect of failure on a scale from 1 10 1 implies no effect and 10 implies a very high and hazardous effect The failure may result from the product becoming inoperative or unsafe and could result in possible injury Occurrence is the probability of failure based on potential cause s over the lifespan of the product This is indicated on a scale of 1 10 where 1 implies failure unlikely and 10 implies failure is almost inevitable Detection relates to the possibility that current controls will detect the potential failure before sending the product to the customer Finally a Risk Priority Number RPN is calculated from these values Otto amp Wood 2001 Table 3 4 FMEA Worksheet Potential Potential Risk priority f Potential Occurrence Current Function Failure Effects of number i Cause s O controls 3 6 Prototyping Prototyping is the process of developing an approximation of the product It provides an efficient and effective method to modify and improve the product through the t
24. ancing the method of validation and evaluation rating the requirement and adding the new requirements The specifications were reformulated for the purpose of justifying the requirements For instance the requirement that starts with Easy to such as Easy to transport to the mining and exploration site Easy to change between transportation medium and Easy to load unload the machine into the vehicle were difficult to define whether it is easy or not After the discussion the requirements were changed to Possible to The changed requirements fulfill the basic understanding that the instrument should be able to do as stated in the requirements The target level was a tricky aspect because if the target level was too high to achieve it might create a problem with the actual production of the machine The preliminary solution was to set the target within a required range and the demand and wish target level After carefully consideration the target level was changed to a more appropriate and accurate value for example the analytical speed is 1imm s to 10mm s depending on the type of material the analysis accuracy would be 100 accurate for the demand The validation and evaluation methods were explored to find the ways to improve the methods and procedures For example to validate the mechanical robustness the instrument should be compared to other machines and equipment that are used in the min
25. ature inside the instrument should be adjusted to within a suitable range so that all the systems can operate properly The solutions of this problem came from different ideas Some ideas were based on the solutions from other machines such as a heater fan and dehumidifier to control temperature and humidity or a single component to control both temperature and humidity would be ideal Other ideas were to use air curtains or controlled air flow to prevent the outside air from contaminating air inside the instrument 4 4 6 Components layout The idea behind the layout was to fit all components inside the instrument In the first prototype the sub systems were located outside the machine including electronic storage cabinet cooling system and High voltage generator Only the analysis components were placed inside the machine In the next product the functions are more complicated than the prototype which means it has more components The challenge of the design was to limit the size of the instrument Other factor that might affect the layout was the sensitivity of the sub systems For instance a high voltage generator will create a magnetic field that might affect other electrical components during the operation Initially two component layouts were proposed to the stakeholders Autodesk inventor was used to create a visualization of the layout At this stage the problems of both layouts were not yet realized However throughout the development p
26. be In general the glass surface should kept clean and dry at all times the cooling circuit inside the tube needs to be inspected and cleaned and the X ray tube itself has a specific life soan and needs to be changed 16 Chapter 4 Concept development e The cooling system requires the checking of the water level and heat exchanger The water needs to be refilled and the filter of the pump are checked and cleaned every 3 months The maintenance information will affect the components layout because the components that require frequent maintenance and regular checking should be placed in the position that s easy to access by the user Regarding the non disclosure agreement the information within the maintenance list cannot be disclosed because it contains a list of the components model and supplier and other sensitive information 4 4 5 Environment The main goal of this thesis is to develop the instrument for field use To achieve that goal the instrument should withstand the harsh environment of the mining and exploration field The factors that can affect the performance of the instrument or jeopardize the operation are temperature and humidity inside the machine because the components of each sub system can withstand a different range of temperature and humidity For example the operating temperature of the high voltage power supply is between 40 to 85 degree Celsius while the X ray tube can operate at 5 to 40 degree Celsius The temper
27. box is along the Y axis direction The tray moves in and out through the feeding hatch 6 1 6 Front hatch The front hatch is used for performing maintenance functions inside the inner cage such as cleaning the X ray tube changing the X ray equipment and regular maintenance for the camera and laser sensor The hatch is made with an aluminum frame and special lead glass which makes it possible to look inside the machine As mentioned in chapter 5 2 1 the open mechanism of the hatch was changed to a normal swing door The hatch is kept shut by a magnetic lock which is activated during the analysis process and a key lock that allows only the authorized person to open the hatch Figure 6 5 shows a rendering of the front hatch Figure 6 5 Front hatch 30 Chapter 6 Result 6 1 7 Feeding hatch The feeding hatch is the most frequently opened hatch because it used for loading and unloading the samples The radiation safety was the primary concern when designing this component It is important to make sure that when the hatch is closed the inner wall and the hatch door are overlapping The hatch is a swing door which opens downwards Figure 6 6 shows a rendering of the feeding hatch Figure 6 6 Feeding hatch 6 1 8 Outer plate The design of the outer plate was modified to match the refinement of the front hatch and feeding hatch For example the front plate was changed so that instead of having mounts with a slanted front hatch the plate jus
28. d forklift E 2 3 Rail Rack Rack PE EE oo 3 4 Handle Selection Criteria Remake Seddon Solution pepeo e 1 Container solution corner hold forklift ES 2 2 Portable PE EC A A ere Appendix F Elimination matrix 55 4 Maintenance 4 1 Cleaning 1 Satay 2 Pressure an E E E E 3 Air 3 Air fiter ES AA Flow further develop Cen COENEN EX AT Flow further develop ps gt fees 6 Clean room Vertical Laminar Flow further develop 4 2 Sub system maintenance samen ER nee e Solution O H 1 1 Separate partition partition ENCUEN GEES EE EE ETC 5 Environment 5 1 Control Environment Air curtain Air curtain 2 Control pressure inside and a the machine 3 Heater Heater Warm Warm environment 4 Temperature and Humidity Controller 56 Appendix F Elimination matrix 6 Layout 6 1 on layout EH The sensitive information was back out according to non disclosure agreement Criterion A Solution proposals are compatible with the overall task and one another Criterion B The solution proposals fulfill the demands of the requirements list Criterion C The solution proposals are realizable in respect of performance and layout Criterion D The solution proposals are expected to be within permissible cost Criterion E Compatible with safety standard and introduce favorable ergonomic conditions Selection Criteria Yes No Lack of informatio
29. d unloading samples affect other aspects the most It influences the function of the movement of the X ray tube and core box control of the inside temperature and component layout The idea generation process was started from this aspect and the result of this aspect can change the direction and outcome of the solution of the other aspects The loading and unloading the core box is a function of how to handle the core box how to import the core box inside the instrument and how to export it after finished scanning The function is divided into two sub functions which are direction and method The solution for the direction of loading and unloading samples is limited by the location of the working site Since the purpose of the product is for field use the only directions that are possible for the solution are in X axis or Y axis See figure 4 4 In contrast the methods of loading and unloading are more flexible Fal F NX e 4 w T pr PS 2 is s ey Ce S a X axis _ Figure 4 4 a b the direction of loading and unloading sample In the beginning of the idea generation process the outcome of the method of feeding the core box were vague and without detail There were only some ideas of how to open and close the hatch The issues about which side of the core box should be loaded and if the core box should be loaded or unloaded from the same door were still under question After the discussions with the company s entrepre
30. d very important 3 medium important 2 between medium and not important 1 not important Note that a rating of 1 doesn t mean that the requirement will not add value to the machine The solutions that were evaluated by the Kesselring matrices are loading and unloading the core box environment control and the front hatch Firstly the method of feeding the core box into the machine the possible solutions are video player the oven sledge and drawer When evaluating each possible mechanism a rating system was applied to each of the following criteria ergonomics safety reliability performance speed size maintenance environment temperature and cost the result shows that the video player option has the maximum total weighted value This means that the best outcome concept for the feeding function is the video player solution The example of the Kesselring matrix Loading and unloading the core box is shown in Table 4 4 Secondly the environment control function the selected criteria focus on controlling the inside temperature humidity control and reliability of the instrument Finally the front hatch the main criteria for each function depends on the selected requirements Some requirements are significant in all functions because it can affect the status of the entire system such as reliability and maintenance Table 4 4 Kesselring matrix Loading and unloading the core box Ei player Sledge Weight Criteria w ES aiie Weighted
31. d with CAD models The thesis is planned to take 6 months to deliver the expected outcome Following areas will be developed during this thesis e Construction of the list of requirements specification e Generate evaluate and select the concepts of loading and unloading sample movement of samples and components maintenance and transportation e Designing the layout of the instrument e Designing the cover e Create a CAD model and drawing Chapter 2 Thesis Process 3 2 Thesis Process The thesis follows the product development process namely e Pre study phase organizing and structuring how the project will flow e Research and conceptual analyses phase to study the current prototype in order to identify the problem and specify the requirement e Development phase to generate evaluate and select the concepts e Refinement and deliverables phase finalizing the concept writing the report and thesis presentation Masters Programme in Product Development 2010 2 1 Pre Study phase In the Pre study phase it is important to clearly state the purpose and scope of the thesis and to make agreements with the company at the beginning of the thesis After starting the thesis a meeting with the company was arranged The main discussion was about the objective of the thesis and what is expected as a result A misunderstanding of the goal and expected result can cause drawbacks to the thesis The thesis description was formulated in order t
32. dditional information and the knowledge gained from the prototype Furthermore the requirements of the new function of the instrument were added into the requirement list The big difference between the existing prototype and the new machine is that instead of a single core scanner the new one can scan multiple samples in a standard core box See Figure 4 2 which means that the developed equipment is a lot more complex than the existing prototype It has new functions such as loading and unloading the core box and the movement of the X ray components Another issue is the company wants the new instrument to be compact by putting every component inside the machine and it must be easy to transport Hence the new design is suitable to be used at the drill site For the new product the new requirements were added and Figure 4 2 The standard core box some of the target levels were changed in order to support the new functions and components of the instrument After discussions with the company the first draft of the required specifications was created The requirements were not complete because some of the values were unknown and some requirements needed to be discussed further in the next phase of the development process For example the performance of the Chapter 4 Concept development 11 instrument such as the analytical speed and analysis accuracy depend on the type of material that the user is looking for The different settings of th
33. e Regularly check the system Regularly check the system Low voltage power Maintenance list supply failed Poor maintenance Maintenance list PLC error Maintenance list Low voltage power Maintenance list supply failed actuator De No electricity Stop working Cooling liquid overheat Not enough Cooling overheat system Poor water flow overheat The sensitive information was back out according to non disclosure agreement Poor maintenance Maintenance list Poor maintenance Maintenance list N 00 o Ww Ww Ww Un N N CH Oo Pump failed Maintenance list E ER N Li Stop working NN Poor maintenance inear 24 Chapter 5 Refinement 5 Refinement During the development of the final product adjustments based on the evaluation methods always need to be made to improve the concept and to combining the good features of some alternative solutions that can be adapted for the product This chapter will describe the refinement of the requirements specification and the refinement of the final product 5 1 Refinement of requirements specification The requirements of the instrument were modified during the development process either because of the hidden requirements that hadn t been realized at the beginning of the thesis or new knowledge and information that was acquired during the process These improvements include clarifying the requirements statement selecting a more accurate target level enh
34. e 3 1 Process flow model 3 1 2 Function means tree Function mean tree is an approach to capturing the functional requirements and decompose them in a hierarchical structure It decomposes the sub functions and sub solutions starting from the primary function The purpose of this method is to define the interaction between the functional domain and physical domains The tool consists of two types of nodes functions what needs to be done and means how those can be done This approach can also be a tool for idea generation Figure 3 2 illustrates a function means tree Function means tree was used in the thesis to provide an understanding of the relationship between functions and the components Ullman 1944 Figure 3 2 Function means tree 3 2 Relations diagram The relations diagram also known as interrelationship diagram is used to identify cause and affect relationships between different issues The relation diagram is created by identifying factors that are involved in the problem draw an arrow from the greater influence the cause 6 Chapter 3 Theoretical Framework to the lesser influence the one influenced The factor with the most outgoing arrows will be the driver or causal factor and the factor with the most incoming arrows will be an outcome or result This tool was used in the thesis to organize the functions of the instrument It identifies causal factors and help to decide which function to focus on Charantimath 2009
35. e Initial concepts e Sketch of the product concepts Phase 2 Nov 8 Nov 30 e Updated list of requirement e Maintenance requirement list e Sketch of updated product concept Phase 3 Dec 1 Dec 18 e Final concept sketches Phase 4 Jan 1 Mar 31 e Production drawing e Sketches Rendering e Documentation e Report The final results of this thesis are the feasible concepts of instrument that can use for production CAD models and report Appendix B Requirements specification Appendix B Requirements specification 41 Performance 1mm s to 10mm s i 3 ARE SPERO Depend on material 5 D W W 4 D E W 5 D Sample is not moving while analyze process 3 Weight D Max 1000kg W Max 400kg 4 Size W The equipment should be able to put in the 180x110x75cm vehicle 5 W Sound level Max 90 dB 3 Power usage D Operating Max 6500 W W Stand by Max 600 W Measure the speed with time and distance travelled Weigh using large scale used for vehicles Weigh using large scale used for vehicles Measure with measuring tape stick Measure with use of a dB meter Measure using a volt and ampere meter Measure using a volt and ampere meter Consultation with expert Repeatable test Compare the result with lab result Prototype testing Used photo to compare the position Photo Assessment using large scale Assessment using large scale Assessment using CAD and measuring tape Relate to wo
36. e equipment with emphasis on following aspects Operability the developed equipment should be able to analyze more rock samples than existing prototype Usability the developed equipment should be easy to use according to ergonomics Safety the developed equipment should be safe to operate Transportability the developed equipment should be easy to transport Environment the developed equipment should be able to operate in the rough and tough environment Design the developed equipment should use small space and low weight The intended outcomes of the thesis are the concepts solution of following functions radiation shielding and cover loading and unloading samples movement and automation of samples adjustment and integration of components cooling system maintenance and transport solution Scope Due to the limitation of this thesis the thesis will focus on develop a concept of field analysis equipment Following areas will be developed during this thesis e Construct the list of requirement s specification e Generate evaluate and select the concepts of load and unload movement of samples and components maintenance and transportation e Design the layout inside the machine e Design the cover e Create CAD models The thesis is not including programing of PLC or control software and no physical production This thesis will not go deep in the subsystem only some suggestion on specific components layout and requirement The de
37. e searched material can change the speed of the analytical process Also some requirements are vague and hard to interpret Another issue that is significant for the instrument is safety with regards to radiation For this both Swedish and EU legislations need to be studied so that it can be implemented effectively The list of requirements consists of the type of requirement either demand or wish the requirement statement target level validation and evaluation verification Table 4 1 shows the examples requirements that have high priorities for the design criteria The full required specifications can be found in appendix B Table 4 1 The requirements Samples should not move If the samples move during the analyzing process it will affect during the analyze process the quality of the result The user can check the position of the sample from the photo Sound level The instrument should not have a sound level more than 90dB as this is limited by work place regulation The sound level can be measured by using a dB meter Operations manual The machine should have a user s manual to help the user understand how to set up and execute the processes Calibration system To help calibrate the instrument in order to get the best accurate result The system should detect the position of the sample Internal storage The instrument should have an internal memory used for recoding the result position and photo of the sample Easy data transfe
38. ed when the outer plate is included the total thickness is sufficient to shield against radiation from the X ray tube The problem is when the user opens one of the cabinets during operation the total thickness of the metal plate is then reduced The design solution is to use the thicker plate on the cabinet side In 28 Chapter 6 Result order to make sure that no radiation leaks out from the gap between the metal sheets the metal sheets were designed to overlap in the corners of the cage The open spaces for the cable inlet and outlet contains the light trap the metal part that forces the radiation beam to bounce a couple of times because the radiation reduces every time the beam bounces in the light trap Figure 6 2 illustrates a rendering of the inner cage Figure 6 2 Inner cage 6 1 3 Cabinet The Cabinet is the separate partition for the sub systems which includes the electronic storage cabinet high voltage cabinet water tank cabinet and computer cabinet Each cabinet was designed to open from outside and cannot accesses to the analysis components The cabinet doors have metal rims and flanges to prevent the water from slipping through the gaps between the cabinet and the door The electronic storage high voltage and water tank cabinets are located at the back of the machine To simplify the design and save production cost instead of having a cage to install the components inside the cabinets have only a back plate attached with the
39. er plate should be at least equal to the thickness of the metal sheet plus 1 mm and the tolerance between two plates in the normal assembly part should be 1mm Finally the hole of the outer plate should be bigger than the hole of the inner plate for instant if the inner plate uses M6 outer plate should use M8 In summary the result of the thesis has fulfilled the specification in a big extent Even though there are some differences between the expect results and the final spec These happen because of the requirements have been changed and the problem that discover during the development process For example as mention before the outcome concept of feeding hatch and front hatch will increase the complexity of the machine The decision was to use a swing door instead Following are the lessons learned during the development of this thesis e The requirements can change During the thesis several requirements have been improved and changed This is the uncertainty that cannot be avoided Allowance and preparation should be made for this one needs to be aware of how these changes would affect future processes e The time plan is important Sometimes the developer can lose sight of the purpose and focus on the wrong thing The time plan is a good pacemaker and ideal tool for keeping all concerned on the right track The deliverables of each stage can help clarify the aim of each phase e The best solution may be unfeasible Even though one
40. esources the exploration drilling process is associated with high investment and major risk Currently mining and exploration companies use a portable XRF analyzer and geologist s judgment to select the core samples from several drill holes reaching hundreds of meters below the ground and send those samples to laboratories for accurate analysis Figure 1 2 illustrates the exploration process This process takes a lot of time and is very costly In view of the information mentioned above it is a great opportunity for the company to develop an instrument that can analyze rock core samples right at the mine and exploration site With this new instrument the process will be shortened since the instrument can produce the scanned result on site more accurate and repeatable than the delivered results by the portable XRF analyzer The samples no longer need to be selected because the developed machine can analyze the entire sample from the drill hole Exploration Sample Sample Investment Pre studies e eh drilling selection analysis decision Figure1 2 The exploration process 2 Chapter 1 Introduction The company decided to produce a single core scanner to reduce the complexity of the prototype The next product will be an improvement on the design and function of the first prototype and will be produced in the future based on the final concepts of this thesis 1 3 Purpose The aim of this thesis is to generate feasible concepts of X ray equi
41. ess This phase is about market understanding customer needs and specification requirements Masters Programme in Product Development 2010 The market research was accomplished by the company to explore the performance of the product in the market the competitor companies that produce rock sample scanning equipment and potential customers from within the mining and exploration industry The first prototype was designed based on the idea from the Product development project A good way to understand the concepts of the existing prototype is to study the product development project report including the market analysis customer needs requirements specification the components and the idea behind the concept in order to develop the concept of the new instrument The issue that was kept in mind during this process is that 4 Chapter 2 Thesis Process some part of the report was not updated and needs to be improved The next step was to study the sub systems and components of the existing prototype and create component structures to show the whole system of the machine The manual of the sub components helps identify the requirements of the sub system A process flow model was made to illustrate the input process and output of the existing prototype 2 3 Development phase The Development phase begins with identifying the function and problem The function mapping was done to show interference between the functions and to find the most effective a
42. esting and iterative revision In the thesis three dimensional computer modeling 3D CAD was chosen to produce the 3D computer aided design models of the actual product Within the thesis the 3D CAD model was used for four purposes Firstly learning the prototype is used as a learning tool The designed part can be adjusted as many times as it is required until the result is satisfactory The estimation can be made to test the outcome and generate discussion for further development Secondly communication the prototype shows the visual of the product It not only enhances the communication with the customer and investor but also the manufacturing process as well The three dimensional CAD model is much easier to understand than a sketch or drawing Thirdly integration the 3D CAD model can demonstrate the assembly of the product to ensure that the components and sub systems fit together as designed Finally as milestones if the prototype fulfills the requirements this can be used as a yardstick at various stages of production to ensure that each stage of the development of the product goes well and will perform as expected Ulrich amp Eppinger 2008 Chapter 4 Concept development 9 4 Concept development This chapter describes the background of the first prototype identifies the problem and lists the functions that needed to be improved The product development process is also outlined in this chapter starting with establishing the required
43. g matrix on Go No Go The sensitive information was back out according to non disclosure agreement Appendix F Elimination matrix 53 Appendix F Elimination matrix 1 Loading and Unloading the core box 1 1 Direction Incompatible with core 1 X axis o movement avast Tle Ll ef 1 2 Method Selection Criteria Ramarks Decision Solution pa e cfole PTT TT aee EE requirement autu EE E LI Steger II E meo 4 The oven EO Pe 2 6 Drawer gt tT eh Le Pe Pe d gt 2 Movement 2 1 X ray components movement Selection Criteria oe ee ene E 1 X ray components move X axis left right Z axis Up down Core box move Y axis In out 2 X ray components move Y axis In out Z axis Up down Core box Incompatible with layout move X axis left right 3 X ray components move Z axis Up down Core box move X axis Incompatible with layout left right Y axis In out 54 Appendix E Elimination matrix 3 Transport solution 3 1 E Protection Machine require 1 Nothing protection during transportation 2 Conner 2 Conner bumper 3 Edge bumper 3 2 Window glass common panel protection e E M Solution Las e Lo E 1 Rollup door coveroneside e 2 Two Roll up door separately ln 3 shutter Tt plo JUnfeasible 3 3 Holding Fixed in vehicle Selection Criteria A Dan Solution O e 1 Container solution Conner hol
44. gene eebe 2 EE 2 ENEE 2 2 Thesis EE 3 ZA Presta Nas ai a ee eee ee ee ee 3 2 2 Research and conceptual analyses phase 3 2 3 Development phases ads 4 2 4 Refinement and deliverables DEE geet eier dd 4 3 Theoretical Framework anita dl 5 gt FUNCUO nana VS AS 5 32 Relations didera e a E daa 5 See e ele EE 6 SA GOMCCDE Ee EE 6 3 5 Fail re mode and ettects anal iii a 7 A A O o A a 8 4 COnceptaeveloo Me tania ds 9 D a Ka E o EE 9 KREESSER SEENEN dee 10 kO REENEN craiobe 12 4 4 Concept SEN el allON ee aan ioaaara 12 EENHEETEN 21 A sn detaaweda have Saudetha ne ty bee stundaNaseanbane dads dun ded eacedoennsaaunts 24 5 1 Refinement of requirements specification essseseesessresssreresrrrrssrrresereessrreesrrrreserresene 24 5 2 Refinement OF the concept ee trees Maree Nees ok ten rae ae nd ER 25 eet eelere 27 AAN DE IN da do da 27 SEET Ee ds 31 EC EE 32 7 1 Thesis process and Theoretical fTramework 32 ZARES EE ER BS RECOMMICHIIC ET WEE 34 CONCISO riada 35 EE Reeder aes 36 Appendix A Planning RED ONE EE 37 Appendix B Requirements specification esssssseesssreressreserrrresrrerssrrresereresreressreessreresereesseeee 41 Appendix C F uncionalanalysiS atar don 47 Appendix D Relations diagr EE 49 Appendix Eet eh EE 50 Appendix ElMMlMatlOn Mt eS 53 Appendix G Kesselring Ee E EE A a 57 Appendix H GUTE ET EE 60 Chapter 1 Introduction 1 1 Introduction This chapter introduces the thesis which includes the
45. he prototype is a visual representation of the concept A CAD model was created by using the Autodesk inventor program It is the best way to design the machine because if the concept is not feasible or too complex to be accomplished in practice the change of design can be made within the program Finally the report has been finished and presented Chapter 3 Theoretical Framework 5 3 Theoretical Framework The method and tool that were used in the thesis including functional analysis relations diagram concept table concept evaluation failure mode and effects analysis and prototyping will be described in this chapter 3 1 Functional analysis Functional analysis is the analysis of the system in terms of its purpose It involves the description of the main function and sub functions of the system Two functional analysis methods were applied in the thesis namely Process flow model and Function means tree 3 1 1 Process flow model The main purpose of a process flow model is to decompose the primary function into sub functions The flows regarding material energy and information between the sub functions are described The method focuses on input operands output operands and transforming function Figure 3 1 illustrates the process flow model This method was used in the thesis to define the flow of the analyzing process of the developed product in order to improve the desired function and design the new function Ullman 1944 Figur
46. ing overloaded circuits 5 D the hatch is open Safety sensor Prototype testing 3 D operation error Emergency stop Prototype testing 5 D Emergency stop button 5 D Warning lamp Green Red Yellow Lights should be integrated and visible from 360 degrees around the machine Appendix B Requirements specification 45 5 W Warning indicator 2 W Warning alarm Acoustic alarm Only authorized person can operate the 5 W y p P Cabinet lock machine access the result 3 W Separate switch between X ray components and other components Assessment by mineral exploration D Basic safety standard EU regulations experts Assessment by Prospecting experts and D Mining standard EU regulations ELSAK FS 1995 6 A i i D Mineral exploration regulations EU regulations es ESsmenE Ny mineral explorari n experts Radiation Safety Authorities rules regarding usage of 5 Radiation standard industrial equipment that contains closed radiation sources and X ray tubes SSMFS 2008 4 Discussion with Swedish Radiation Safety Authority SSMFS 2008 4 lonizing radiation type description the D Warning sign machine contain a X SSMFS 2008 4 SSMFS 2008 25 ray tube Shield the radiation before entry D Radiation protection Controlled 1 per year SSMFS 2008 4 Not exceed 7 5 uSv h D Radiation dose rate where a person can SSMFS 2008 4 pass by Not exceed 2 5 uSv h where a person is SSMFS 2008 4 permanently located Not exceed 2 uSv h at 0 1 meters fr
47. ing industries For the safety function it is stated in the initial requirement that the instrument should automatically shut down the X ray tube when the hatch is open but when considering the maintenance aspect it might occur that the user needs to open some hatch such as the computer cabinet or the electronic storage cabinet while the machine is operating The final product considers both the safety and maintenance aspects by designing an inner cage that prevents radiation leakage In order to comply with this design the requirement was added that the safety sensor be applied only to the hatch that leads to the X ray tube so the user should still be able to open the electronic storage and computer hatch while operating The main specification change that affected the design is the size of the core box The original intention of the design was to have a core box size of 1042 mm x 378 mm x 50 mm but during the development new information came to light that the standard size of the core box varies depending on the country that uses it Thus the new dimension of the core box is 1100 mm x 362 mm x 50 mm making the length of the new core box longer than the first one Chapter 5 Refinement 25 5 2 Refinement of the concept The result from the evaluation methods is only the concept To make it more feasible the refinement was needed to fill in the missing detail Following are the concerns of the instrument and the solutions to overcome the prob
48. lems Some of the concerns were discovered during the 3D CAD modeling process 5 2 1 Loading and unloading the core box and feeding hatch For the method of loading and unloading the core box the mechanism called video player was chosen The concerns of this system are the lack of detail about the moving parts how to open the hatch and how it works The modified version of the video player integrates the strength of the Drawer concept The improved concept satisfies all the concerns The main features of the mechanism are the movement of the feeding tray and the hatch The hatch was designed as a lifting door which could open upwards or downwards After investigating both options the conclusion was that the best solution is to open downward because the top of the hatch could be used to attach the roller or other material to support the tray when loading the core box The hatch should have a physical lock as well as the mechanism to prevent it from falling down Research was conducted to find an example of a product that used such a system The suppliers that can provide a similar type of product were found The problem of this solution was realized later Because of the size of the feeding hatch it is not only impossible to make a lifting hatch that has a counter weight mechanism but also extremely expensive for a motorized solution After discussions with the stakeholders the decision was made to reduce the complexity of the design b
49. logy was nonexistent or not well known yet The choices the development team made for the final concept was the best solution for the situation at that time The existing prototype is a single core scanner lt can only analyze rock samples that are smaller than 0 5 meters at one time The instrument uses an X ray fluorescence XRF technique for the analyzing process XRF is a non destructive analytical technique used to analyze rocks minerals sediments and fluids According to Beckhoff Kanngiefser Langhoff Wedell and Wolff the XRF principle can be explained as follows When the inner electron is excited by photons in the X ray the atoms becomes unstable and an outer electron moves from a higher energy level to fill the gap of the missing inner electron During the process energy is emitted due to the energy difference between the two shells The released spectrum reveals a number of characteristic peaks that can be used to detect the identification of the elements that exist in the sample During the study phase the component structure was created to make an understanding of the entire components The main sub systems of the prototype are power system motor system X ray system cooling system controlling system or PLC chassis and user interface The aim of studying the sub systems and its components is to find an answer to these questions What are the functions of the components and Why does the instrument need it These ques
50. n Check requirement list Decision Pursue solution Eliminate solution Collect information 1 Check requirement list for changes Appendix G Kesselring matrix 57 Appendix G Kesselring matrix 1 Loading and unloading core box Performance Speed 4 0 11 Weight 3 0 08 Size 4 0 11 Ergonomics Safety 5 0 13 Reliability 5 0 13 aesthetic design 3 0 08 Maintenance 4 0 11 Control Environment Temp 4 0 11 Production 2 0 05 Cost 4 0 11 Video player Sledge Drawer Criteria Weight vaie Weighted Value Weighted Value Weighted Weighted w v1 Value Wo Value v3 Value Value W V1 W V2 W V3 W V4 wm 0 66 a a Total 191 aos zen Control Environment Temp 0 11 gt gt 58 Appendix G Kesselring matrix 5 Control Environment Control inside 5 0 19 temperature Control Humidity 5 0 19 Prevent temperature rise drop during load 2 0 07 and unload core box Reliability 5 0 19 Maintenance 4 0 15 Production 2 0 07 Cost 4 0 15 Heater Fan Temperature Control Air Ge Air curtain and and Humidity flow a o Weight Dehumidifier Controller Criteria W Weighted Weighted Weighted Weighted Value Value Value Value W V1 W V2 W V3 W V4 Control inside temperature Control Humidity 0 19 Prevent temperature rise drop during load and unload core box 1 00 HE osa Cos el Appendix G Kesselring matrix 59 8 Front Hatch Access
51. n Australian climate Prototype testing D Min 20 C Servicing in arctic climate Prototype testing 5 Inside Temperature 44 Appendix B Requirements specification D Operating 10 C to 25 C The equipment are sensitive due to sub system Prototype testing D Storage 20 C to 55 C The equipment are sensitive due to sub system Prototype testing 5 D Humidity 35 to 80 RH The equipment are sensitive due to sub system Prototype testing Dehumidifier 4 D Resistance to water The equipment are sensitive due to sub system Prototype testing 4 W Resistance to dust The equipment are sensitive due to sub system Consult with experts 4 W Resistance to dirt The equipment are sensitive due to sub system Consult with experts 2 W Ge BEER The equipment are sensitive due to sub system Assessment using CAD 5 W Prevent the water from the box from sensitive component 3 W Be able to drain any excess water out of the machine 3 Corrosion resistant D 10 years Customer expectation Engineering assessment W 15 years Engineering assessment 4 Vibration resistance D Light vibrations during operation Due to machinery in close vicinity W Unforeseen large vibration shock Accidental drop 4 W Prevent sudden impact to X ray tube Podon 2 W Number of parts Max 1000 Assessment using CAD 2 W Production time 100 man hours Assessment using DFA Automatically shut down x ray tube when electrical problems intermittent power 3 D power surges redundant wiring and Prototype test
52. n based on Go No Go screening and the Kesselring matrix 3 4 1 Elimination matrix The Elimination matrix is a filter for the concepts The evaluation is based on feasibility judgment An idea will be excluded if it fails to fulfill one of the following criteria solving the main problem fulfilling the demands of the requirement list realizable in principle reasonably cost effective and safe Each solution will be judged against the criteria The result can be Yes No Lack of information or Check requirement list And the decision for each solution can be Pursue solution Eliminate solution Collect information or Check requirement list for changes In the thesis this method was used to eliminate obviously disqualified solutions It is a quick step before concept screening and concept scoring Table 3 2 shows the Elimination matrix Pahl Wallace amp Blessing 2007 Chapter 3 Theoretical Framework 7 Table 3 2 Elimination matrix AJ etoj E 2 O IO OO OS IO IES FE a O O OS EE eee eee ECH SE ee ee eee eee ce lo dla A 3 4 2 Evaluation based on Go No Go screening After that the concepts have passed the Elimination matrix they will be evaluated against the criteria defined by the requirements specifications The questions that generate from the requirements need to be answered with either Go or No Go This method was modified to make it more suitable for the thesis Instead of using the matrix
53. nd affected functions The next step is to generate the concepts The ideas were established and sketched to visualize the instrument A brainstorming session with the company s representatives was set up to help develop the idea and to discuss alternative solutions The concept table was used to present ideas and solutions of the whole system The concepts were narrowed down by using evaluation methods such as Elimination matrices the evaluations based on Go No Go screening and the Kesselring matrices The Elimination matrices helped to eliminate unfeasible ideas The evaluations based on Go No Go screening were used to screen the concepts Finally the Kesselring matrices were used to select the promising ideas by applying rated criteria that were selected from the requirements after the discussion with the company s representatives The outcome concept is the result from using evaluation methods It contains the solution of each function that suited the product It is however possible that during the product development process the requirements might have changed or some solution might not be able to be applied to the equipment The outcome concepts need to be refined in the next phase 2 4 Refinement and deliverables phase In this phase the outcome ideas were refined and finalized by assuring that the idea solutions are feasible and working well together After establishing the final concept it is important to create a prototype of the product T
54. neurs some preliminary ideas were put forward A new loading and unloading solution called video player was proposed It s based on the same principle as a video player The examples of the methods of feeding the core box are shown in figure 4 5 a f 14 Chapter 4 Concept development a Rotation Loading and unloading the sample by rotating the feeding disk b Lift up The sample cabinet fits under the machine The core box is then lifted up to the start position Unloading happens on the other side of the machine c Video player Insert the core box horizontally inside the machine d The oven The feeding hatch opens like an oven door e Sledge As the hatch swings up the sledge slides out f Drawer The hatch slides out like a drawer Figure 4 5 a f Loading and unloading idea solutions 4 4 2 Movement of the X ray components and core box The movement of the X ray components and core box are complicated aspect because the mechanisms of these functions can affect the size of the instrument The purpose of the thesis states clearly that the developed instrument should be compact and as small as possible According to the requirements the size of the machine is limited by the width of a standard door 80 cm The height is 75 cm being the same as the existing prototype The length of the machine depends on the core box size and the mechanism of this function Chapter 4 Concept development 15 The movement
55. ng usage of industrial equipment that contains closed radiation sources and X ray tubes Swedish Radiation Safety Authority SSMFS 2008 4 Figure 4 3 The illustration of drill site On the left the drilling machine To the right the stack of core boxes 4 3 Functional analysis The functional analysis was conduct at the beginning of the development process in order to identify the primary function and the sub functions of the instrument The analysis was based on the study of the existing machine s function By improving the desired functions and adding the new functions that correspond to the requirements the functions of the developed machine was established Two functional analysis methods were use in the thesis the process flow model and the function mean tree Both methods are useful for decomposing the main function into sub functions The process flow model gives a good understanding of the flow of operands including material energy signal and information while the function mean tree explains the relationship between the functional domain and physical domain The primary function of the new instrument is to analyze rock samples This can be broken down into sub functions load the core box detect the core box move the core box move the analysis equipment analyze the samples and unload the core box The process flow model and function mean tree can be found in Appendix C 4 4 Concept generation From the study of the first pro
56. nt of the previous stage The deliverable of the first stage is the list of requirements The second stage requires the possible product concept Finally the requirement of the third stage is the potential concept In summary the design methodology provides a very useful approach for the development process The methods were selected and used as tools to facilitate meeting the goal of each process The common question that arose during the process was which methods are suitable for the development of the instrument For the function analysis process the flow model and function mean tree were chosen Even though both methods have the same primary purpose which is to decompose the main function into sub function the process flow model was used to show the flow of the input operand function and output operand The function mean tree was used to map the functional domain and physical domain The use of the concept table was developed for this specific thesis The intention of the use of method was to collect the solutions in one table then use the concept evaluation methods to evaluate each solution The reason behind this is because the functions of the instrument have individual properties The best way to simplify the evaluation process is to select the solutions from each function The choices of evaluation methods are also a discussion issue for instance the evaluations based on Go No Go was applied in the concept screening process The reason for
57. o briefly describe the topic The description includes the background purpose objective scope stakeholders method time schedule and deliverables This document was used to register the thesis The meeting between the examiner and the company was set up to discuss the confidentiality agreement of the thesis outcome A planning report was written and used as a guideline for the thesis The report contains the same topics as in the thesis description but with more information and detail such as the introduction of the company the background of the first prototype scope of the thesis as defined by the specifications of the company and a Gantt chart which shows the activities related to timeframes during the thesis This chart is used as a constant reference It defines the duration of each product development phase as well as the schedule of each stage gate and task See the planning report in Appendix A The requirements of the new instrument were specified not only based on the requirements specification of the first prototype but also based on some new requirements due to the new functions new components and more specific target level 2 2 Research and conceptual analyses phase Product development is a methodical thinking process based on the knowledge and creative reasoning which was applied to this project In order to gain the knowledge about the product to be developed the research and conceptual analyses phase is the most important proc
58. of the X ray components and core box should be consistent and work well together The scanning area should cover the entire sample in the core box Three possible solutions were realized In later stages the two of the solutions were eliminated because it was realized that the core box cannot move along the X axis Hence there was only one option for this function An animation of the movement of the X ray equipment and core box was made by using Autodesk inventor for visualization and presented to a big Swedish mining company and potential customers 4 4 3 Transport solution For the transport solution the first discussion with stakeholders focused on how to deliver the instrument to the customer safely Since the machine consists of sensitive components it is important to make sure that the instrument before and after transport is in the same state and be able to set up and run as fast as possible In later discussions it came out that the possible solution for delivering the instrument from point to point for example between drilling site or from the company s office to working location is to use sub contractors because the instrument is of very high value Sub contractors will be responsible for any damages to the machine during transportation The next topic within transportation is how to protect the instrument from damage during transportation and how to place the instrument inside the vehicle The transport solution focuses mainly on
59. of the criteria is manufacturing ability the evaluation could be based on the judgment of stakeholders who lack the expertise in that area To ensure that the design is feasible consultation with the experts is required e There is no perfect design in real world In the computer aided design program the components can be created and assembled easily but in reality the assembly process is more complicated The design should consider practicalities such as the tolerance as well 34 Chapter 8 Recommendation 8 Recommendation The developed product is the new developed equipment for a core box scanner The first model was simplified due to time limitation and resources For further development there are many opportunities for improvement This chapter will explain the recommendations and actions that could be taken First of all some of the functions from the final concept were not applied in the final design For example for the transportation solution the idea of adding corner bumpers rolls up door and forklift pockets were proposed during the development process The stakeholders also agreed with these concept solutions Unfortunately the practical solution could not be identified within the thesis due to the time constraints The suggestions are that a study of the method and material that would be suitable for those functions should be made The electrical components and electronic control system should be developed The sketch of
60. om the SSMFS 2008 25 outer wall Radiation source is not exposed to SSMFS 2008 4 abnormal mechanical stress Closed and locked shutter when the D equipment is not used during the SSMFS 2008 4 maintenance Locked and fire safety storage area that i ea SSMFS 2008 4 contain radiation source The system has two independent systems D that hinder exposure to any person entering SSMFS 2008 25 the space 46 Appendix B Requirements specification Instructions on where to find handling instructions regarding the closed space and SSMFS 2008 25 the name of the contact person lit only when the D Warning light hain ok SSMFS 2008 25 radiation is present 5 W light trap The CE marking is mandatory in most parts of Assessment using FMEA 89 106 EEC D E CE marking regulation Europe and 2006 42 EC 2 W Inspection table 2 W Stand 2 W Wheel The sensitive information was back out according to non disclosure agreement Appendix C Functional analysis 47 Appendix C Functional analysis Process flow model PLC High Voltage H Load core box gt Core box A1 Motor Controller Detect core box A2 Move core box A3 Move X ray components Sensor A4 Analyze sample AS core box Unload core box gt gt Result Cooling iay A6 id equipment User Interface NODE TITLE Process Flow Model NO 48 Appendix C Functional analysis Function mean
61. or maintenance of the components inside the analysis chamber such as the X ray tube was inspire by the doors of a bus garage door etc Examples of the possible solutions are shown in Figure4 6 Figure 4 6 a d Possible front door solutions The cover of the instrument was designed by Niklas Arthursson Product designer The design was based on the idea solutions stemming from the idea generation process The requirements for the outer design are the instrument should be strong durable and compact but still be visible as high tech equipment After discussions with the stakeholders in this project the final design of the outer parts was selected Figure 4 7 shows the final design of the instrument Figure 4 7 Final design of the instrument 18 Chapter 4 Concept development 4 5 Concept evaluation During the idea generation process the possibility of each process such as the loading and unloading the core box movement of the X ray components etc was discussed with Niklas and the company s entrepreneurs and feedbacks were given to improve the concepts Some concepts were unfeasible or do not correspond with the requirements In the meeting the aspect that should be focused on and problems that came up during the development process such as the structure of the chassis inspection table and warning light were discussed In the thesis the concept table presenting in Table 3 1 was created for collecting alternative solutions
62. outer protection and securing the instrument The special care must be taken to protect the window and the panel and securing the instrument in the vehicle The solution was inspired by the protection process from different ideas such as the fire truck that uses roll up doors to protect the inside equipment and the container solution that has special attachments whereby the instrument will be secured Another possible solution would be to make forklift pockets for the forklift to be able to move the instrument 4 4 4 Maintenance The maintenance list was created by listing the maintenance requirements of each component in order to design the layout for further processes The component manuals are the significant source of information The dimensions and technical data such as operating temperature can be found in these manuals The maintenance list consists of the list of components in each different sub system the model of component weight operating temperature storage temperature humidity list of maintenance activities and installation notes The list does not only consider the components of the first prototype but also includes the new possible components that might be involved in the new instrument The maintenance list gives the information about how often the user needs to access the components Some sensitive components need special treatment and more dedicated attention than others Some examples of maintenance would be e The X ray tu
63. ower supply failed NS Maintenance list WEA Magnetic lock Not connect to Safety PLC Cannot control door lock 5 boosewires Maintenance list a No electricity Not working aC High voltage power supply failed SS Maintenance list Sa Does not detect when user Cannot give the command to light sensitive Touchscreen Maintenance list er screen the machine NN Not connect to Not connect to computer Cannot Cannot control the system the Cannot control the system Loose wires wires Maintenance list Maintenance list Radiation leak MEN Poor material selection Regularly check radiation level al ue Radiation leak ECH Poor material selection Regularly check radiation level DE E Chassis User s injur al ne Kg leakage radiation leak Poor Poor degen 2 Regularly check radiation level Front hatch Machi Fall down lw SS Soe lees Lock is not working Ee Regularly check the system a a Feeding hatch The sensitive information was back out according to non disclosure agreement Touchscreen Appendix H FMEA worksheet 63 Severity No effec Very minor only noticed by discriminating customers Minor affects very little of the system noticed by average customer 4 5 6 Moderate most customers are annoyed High causes a loss of primary function customers are dissatisfied 9 10 Very high and hazardous product becomes inoperative customers angered the failure may result unsafe operation and possible injury Occurrence
64. pment based on the first prototype for performing field analysis of rock samples in mining and exploration applications The developed equipment will be capable of analyzing multiple samples in a standard core box 1 4 Objective The objective is to develop and redesign the current prototype equipment with emphasis on the following aspects e Operability the developed equipment should be able to analyze more rock samples than the existing prototype e Usability the machine should be easy to use according to ergonomics e Safety it should be safe to operate e Transportation the instrument should be easy to transport e Environment the equipment should be able to operate in the rough and tough environment e Design the instrument should be relatively small and light weight The intended outcomes of the thesis are the concepts solutions for the following functions loading and unloading the core box movement of X ray components and core box transport solution maintenance environment components layout safety and outer design 1 5 Scope Within its parameters the thesis focuses on developing a concept of field analysis equipment The thesis does not include programming of PLC or control software operating software user interface software and no physical product This thesis does not go deep into the subsystem However it does make suggestions on specific components layout and requirements The developed equipment will be presente
65. ponents and core box For the safety aspect which is the most crucial criteria of instruments using X ray equipment the EU legislation clearly states that portable equipment that contains a closed radiation should have a well displayed warning light which is lit only when the radiation is present By putting the warning lights on the corner of the instrument it helps fulfill the legislation s requirement If an unexpected event occurs the instrument has an emergency stop button to end the process immediately The most serious issue is the radiation safety With regards to safety the main design goal was to prevent the exposure to the radiation The user is not allowed to handle the X ray components while the equipment is scanning in any circumstance The key lock magnetic lock door sensor and the use of a key to start the machine not only solves the radiation safety problem but also limits access to the control panel sub system cabinet and sensitive components to an authorized person only The magnetic lock was installed to secure the front hatch and feeding hatch The lock responses to the safety PLC Chapter 4 Concept development 23 signal which closes when the X ray shutter is open The door sensors detects that the hatch is in the right place and closes securely and gives permission to start the analyzing process The Front and feeding hatches of the instrument were designed with the intention not to allow the user to interfere with the
66. proposal objective and scope In addition the current situation of the market within the exploration and mining industry and the motivation of this thesis are also discussed 1 1 Background The mining and exploration industry is growing every year In Sweden alone a lot of new projects are moving towards production In the upcoming year the newly established mines are scheduled to start production and existing mines are expanding their production For example Dannemora iron ore mine north of Stockholm is planning to start production in 2012 The Northland resource in the north outside Pajala on the border to Finland is scheduled to expand their production to five million ton in 2013 Figure 1 1 Value of exploration in Sweden 1982 2010 shows that in 2010 investments in exploration rose to 675 million SEK The number of exploration permits rose by 40 in the first quarter of 2011 and 192 permits were granted up until September 2011 while another 50 are being processed at the Mine Inspectorate in Lule 323 Exploration permits have been granted extensions and a further 95 decisions are pending Tomas From 2011 Million Kronor 300 A 100 600 500 400 300 200 100 1990 2000 2010 MA State subsidies M Former mine authority MM Othe Source SGU Figure 1 1 Value of exploration in Sweden 1982 2010 million SEK current price Tomas From 2011 In order to find the economically feasible mineral r
67. r with A security system that allows only an authorized person to get authorization lock access to the data Ergonomic The working process should consistent with the regulation AFS 1998 1 Belastningsergonomi Machine reliability The reliability rate should be within 96 of operating time to fulfill the customer s expectation The analyzing process The sample before and after the analysis should be in the same should not affect the state sample Machine protection During transportation it is important that the machine is suitably protected as the sensitive components could get damaged Portability It is essential that the machine can be transported to the work site Rock sample core box The machine should be able to input a standard core box and scan the rock samples in both cylinder and half cylinder form either small or large iron core Environment Protection from the environment in terms of inside temperature humidity and water that leak from the core box Figure 4 3 shows the environment of drill site 12 Chapter 4 Concept development The system should shut down the machine automatically when the hatch is open or the emergency stop button is activated to prevent exposure to radiation The instrument should have warning indicators such as a warning lamp integrated and visible from 360 degrees around the instrument Radiation standard This must be in accordance with the Swedish Radiation Safety Authority s rules regardi
68. rk place regulations Consult with experts Consult with experts Set up time 3 W Physical set up Max 2hr 4 D System set up Max 5hr User Interface Touch screen monitor Working standards Consult with user 42 Appendix B Requirements specification 5 D Operation manual Consult with user 2 W Service log Consult with user 5 D 4 D Intuitive command Consult with user 4 D Automatic control system Consult with user Separate mode Operator interface 4 D Automatic mode and Geologist interface Advance mode 4 W Easy to change the analysis function Consult with Geologist User friendly 4 W The geologist learning time Max 24h Engineering assessment 4 W The operators learning time Max 8h Engineering assessment Data 5 D Internal storage Internal memory internal hdd Visual and functional assessment Integrated USB pref Type A connections for 4 D External Storage Visual and functional assessment external drives available 5 D Easy data transfer with authorization lock Ergonomic Simulation CAD Check AFS 1998 1 5 D Meet standards Work regulation de Belastningsergonomi 5 D Machine reliability 96 operating time Customer expectation Mechanical calculations 3 W Product lifetime NN WEEN Component lifetime assessment 3 W Mechanical robustness Mechanical calculations 3 W aesthetic design Assessment using CAD 5 D The analyzing process doesn t affect the sample Consult with experts 5 D The machine protection while tran
69. rocess the layout has been redesigned and improved many times The details will be discussed in the next chapter Refinement Another issue regarding components layout was the design of the X ray equipment Measurements of the X ray parts were conducted in order to get the dimensions of the components 4 4 7 Safety The safety of the machine is really important This aspect was considered to be the first priority for the design factor The safety function of the instrument was based on the Swedish Chapter 4 Concept development 17 Radiation Safety Authority s rules regarding usage of industrial equipment that contains closed radiation sources and X ray tubes The safety functions included a warning light alarm system and security system For the warning light the user should be able to see the light from a 360 degree view around the machine The possible solutions were to either put one light on top of the machine or install four lights on each corner of the machine The alarm system involves an emergency stop status light or alarm sound Lastly the security feature was to prevent the user from get exposed to the X rays In other words the door and hatch of the components that connect to the analysis cage should be securely locked as to avoid X rays getting out The solutions for this include a key lock magnetic lock door sensor and to use a key to start the instrument 4 4 8 Outer design The design of the front door that is used f
70. s of the instrument that were designed in this thesis consist of the profile structure inner cage cabinet analysis equipment feeding components front hatch feeding hatch and outer plate The 3D CAD modeling was chosen as a prototyping tool to create the 3D model and production drawing 6 1 1 Profile structure The profile structure is the aluminum frame that supports the inner cage and the outer plate The total height of the instrument was expanded because the legs The reason why the instrument needs the legs is for the transportation The machine requires a gap between the body and the ground at least 130 mm in order to fit the forklift forks Because the main function of the frame is to receive the load from the equipment the beam that is used as the main structure is thicker than the rest Triangular profiles were placed at the corners of the structure for aesthetics and for the installation of the warning lights on the top of the profile Figure 6 1 shows a rendering of profile structure created by using the computer aided design software Autodesk Inventor Figure 6 1 The profile structure 6 1 2 Inner cage The inner cage was designed to separate the X ray beam from the user and other components It is important that the primary beam of the X ray cannot be reached by anyone at any time The crucial factor that needs to be considered when designing this part was the radiation safety The thickness of the metal sheet required is realiz
71. sport Possible to transport to mining and exploration 5 D l field 3 W Possible to change between transportation medium Possible to load unload machine into the 3 W vehicle 3 W Stable the machine while transport Appendix B Requirements specification 43 Type Core Geometrical form Test on prototype and or consultation 5 D Cylinder core Sample from core drilling WEE Experts 5 W Half cylinder core Sample from core drilling oe anar emule on Weight 5 Small iron core 0 208kg 100mm 5 Large iron core 0 588kg 100mm Standard core box 5 D Weight Test on prototype and or consultation Empty 3 1kg Standard sample core box With Experts Small iron core x 8 slot 19 74 Large iron core x 6 slot 38 38 104 2 i T Itati 5 D Size 04 2cm x 37 8cm x rand and lt anplecere box est on prototype and or consultation 5cm with Experts T Itati 3 W Powder form Sample from RC drilling EECHER with Experts Due to the need for maintenance of sub system i 1 4 W Easy maintenance year High voltage Consult with experts Access to sub system for 4 D Due to the need for maintenance of sub system Consult with experts maintenance exchange of part 4 W Separate sub system partition Due to the need for maintenance of sub system Consult with experts Due to the need for maintenance of sub system X 3 D Inspection monthly Consult with experts ray tube Check cooling pump every 3 months 4 Ambient Temperature D Max 50 C Servicing i
72. stance to refill the water drain the water out of the system and cleaning With this solution the electrical cabinet can be expanded because the cooling system cabinet will use less space than in the first layout 5 2 3 Core box dimension The most critical issue was the discovery of the new dimensions of the core box Since the machine was designed to use the standard core box 1042 mm x 378 mm x 50 mm the new box is 1100 mm in length which can jeopardize the design of the machine The reason behind 26 Chapter 5 Refinement this is the transportation issue The discussions came to the conclusion that the instrument should be limited to 1600 mm long After exploring the design options the stakeholders acknowledged that it is not possible to scan the whole length of the 1100 mm core box The best option in this case is to design the machine that can load 1100 mm core box and scan the core sample as much as possible In the final design the scanning result will miss a few millimeters at the right end of the core box Chapter 6 Result 27 6 Result In this chapter the final design of the instrument and the limitations of the design will be described The topics focus on the feasible and ready to produce concept the three dimensional computer modeling 3D CAD and the problems that arose during the 3D CAD modeling 6 1 Final Design After the refinement process it is time to finalize the concept and design the components The main part
73. t mounts with a horizontal front hatch The warning lights were placed on the corners of the triangular profiles instead of being mounted on the wall Finally a modification of the roof was required because the heat exchanger will be positioned on top of the machine The roof was intended to prevent the water from getting inside the machine that why it is sloped at a slight angle to make the water flow down from the roof Figure 6 7 illustrates a rendering of the instrument Figure 6 7 The instrument Chapter 6 Result 31 6 2 Limitations Because of the time limit and the lack of information at the time the design and CAD model of the instrument could not be fully completed With the intention of reducing the uncertainty as much as possible a list of limitations was made to indicate the tasks that could not be done or need to be investigated for more information Below is the limitation list e The roll up door that covers the front hatch and touch screen cannot be placed inside the machine as per the intended design Because of the space limit e The CAD model of the electrical components could not be completed because the time limit and the list of electrical components were not finished either However the estimation of the components and initial sketches were created to confirm that all the electrical components can fit inside the electrical cabinet e The cooling system could not be finalized because new information from the supplier
74. the evaluation was carried out in the meeting between the stakeholders The discussion stemmed from which requirements should be selected to create the criteria preceding the screening process Ullman 1944 3 4 3 Kesselring matrix A Kesselring matrix as shown in Table 3 3 is a concept scoring method It is used to analyze potential concepts and finally selecting the final concept The processes of the Kesselring approach are e Choose the criteria based on requirements e Determine the weight factors e Assign the grades for fulfillment of the selection criteria e Calculate the concept scores The final concept is selected from the best total score The Kesselring matrix was applied in the thesis to evaluate and select the final solution of an individual function The selection criteria and weight factors were carefully considered by the stakeholders Each solution was assigned a numerical value corresponding to the level of fulfillment of the selection criteria Ulrich amp Eppinger 2008 Table 3 3 Kesselring matrix Evaluation Weight e V1 V2 Vin PBT We TI Ve We Van Ve Wa Van Ve Was aa dl ee NEEN A PO Y LG Iwwel ZW 3 5 Failure mode and effects analysis The Failure mode and effects analysis FMEA is a technique for identifying failure potential and its consequences and the methods to reduce the chance of failure occurring FMEA is used 8 Chapter 3 Theoretical Framework as a design evaluation tool and as
75. tions are addressed by studying the manual of each component and then making a components list by categorizing the components into sub systems and listing the important requirements and specifications of each sub system In addition a list of pros and cons of each component has been made Some components might not be suitable for the next 10 Chapter 4 Concept development product such as a high voltage generator with improved technologies a smaller model with higher power is available and also a laser sensor that can be useful for the developed product was found since producing the first prototype The cooling system of the prototype is huge and it would probably be better to change it in the developed product of which equipment size is a crucial requirement The purpose of the instrument is to analyze rock sample which in the prototype case is only a single core at a time but the next machine is aiming to analyze multiple samples in a standard core box Figure 4 1 displays the single core scanner Figure 4 1 The first prototype 4 2 Requirements specification The requirements are based on the requirements of the existing prototype and the requirements of its sub systems and components The problem is that the requirements of the existing prototype has not been updated and are unclear because of its lack of detail hard to measure and the limit values are not appropriate The requirements list of the developed instrument was formulated with a
76. to sub system 4 0 12 Ergonomics 5 0 15 Safety Radiation 5 0 15 Reliability 5 0 15 aesthetic design 4 0 12 Maintenance 4 0 12 Production 2 0 06 Cost 4 0 12 er Weight Criteria ge value Weighted Value Weighted v1 Value Wo Value W V1 W V2 Normal door Weighted Value W V5 Weighted Value W V3 Weighted Value W V4 Ex ul O JO JO JO JO JO O RD A Dd o A an DO IO 00 je k je Ex fem am system 0 12 E LA Production 0 06 a Es o o o o o o jo lo O IN IA DM IOA ITD Iie A e A VO Iie je n D D O D 00 un lt ul 3 79 lt Ww 60 Appendix H FMEA worksheet Appendix H FMEA worksheet ltem Function Risk priority Detection D Severity Occurrence S number RPN Potential Failure mode Potential Effects of Failure Restart Stop the machine to i e PDE TR cai Maintenance list PA 36 a error or extensive Potential Cause s 0 Current controls a eee ia Mo E RAI CESE MI TT JL een O wy C O restan Ja a ASA Op Human error or extensive Screw loose AA ANN a Menual Training A ONO No e Cannot KE scanning Low A power supply Low voltage power supply failed Maintenance list Maintenance list A RRA ASA E Tee a mmm emm Trommel CET O EP AAA ES E ora Jason 13 Jresesoreno IL Jeer le EE EE fe fs a ower suppl S Ae Accident Careless user Poor Exposure to electrical shock
77. totype the problems and the functions needed to be improved were identified The main functions are load core box detect core box move core box move X ray components analyze sample and unload core box The next step is to select the design aspects Regarding to the main functions and the requirements of the instrument the aspects considered to be designed are loading and unloading the core box movement of the X ray and core box transport solution maintenance environment components layout safety and Chapter 4 Concept development 13 outer design Mapping the aspects by listing them according to functions and then using the relation diagram to illustrate how these aspects affect each other was found to be most effective The aspect that has an arrow coming out has the greater influence the cause on the other hand the aspect that has the arrow coming in is influenced The relations diagram See Appendix D shows that the most influencing design point is the loading and unloading of the core box and the aspect that is affected the most by other functions is components layout From this point the concept generation was started by following the order from the diagram beginning with the aspect that is not affected by the others then finding solutions for the problems that are more complex and caused by the design points that have already been solved 4 4 1 Loading and unloading the core box According to the relations diagram loading an
78. using the Go No Go approach was because the stakeholders could be involved in the evaluation process and the discussions of pros and cons This method is the fast and easy way to narrow down the concepts 7 2 Result The result of the thesis is the CAD model and drawing of the instrument Due to limited time and resources the final concept was modified to create the final design that is produce able and to reduce the manufacturing cost The feeding hatch was one of the concerns during the development process The first idea was to open it as a lift up door with the opening mechanisms either motorized or counterweight After consulting with several suppliers it turned out that the concept was not feasible because the hatch is too small to install the Chapter 7 Discussion 33 mechanism In the end the hatch was simplified and used as a swing door that opens downward Regarding the feasibility and the cost issue the final design was presented to the manufacturing workshop that produced the first prototype The meeting with the manufacturing workshop gave very useful information regarding the manufacturing For instance in the CAD model all the sheet metal can be assembled by using and indicating the accurate dimension However for practical reasons the sheet metal plate cannot be used without a measure of tolerance Hence the design should consider the tolerances between two metal sheets In the corner the gap between the folded plate and the oth
79. veloped equipment will be presented with CAD models The thesis will take 6 months to deliver the expected outcome 38 Appendix A Planning report Stakeholders The main people who working on this thesis are Vasupol Kunavuti Product developer Mikael Arthursson CTO at the company Annelie Blomdahl CEO at the company Niklas Arthursson Product designer Hans Johannesson Advisor and examiner at Chalmers University of Technology Method The thesis will follow the product development process Begin with Pre study phase organizing and structuring how the project will flow Research and conceptual analyses phase studying the current prototype to find the problem and specify the requirement Development phase is to generate evaluate and select the concepts Finally refinement and deliverables phase finalizing the concept and write the report In Pre study phase it is important to clearly state purpose and scope of the thesis and making agreement with the company Thesis proposal was created in order to briefly describe the background purpose objective and preliminary time schedule of the thesis Research and conceptual analyses phase is to make an understanding of the concepts of existing prototype to be able to develop concept of the new prototype Studying the sub system and component of the existing prototype and create component structure Process flow model was made to illustrate input process and output of the existing prototype
80. which had not been accounted for An investigation needs to be done to explore alternative solutions e Some small detail could not be decided on until the selecting of the parts was done For example the fastening hole for the handle the key lock and door catch on cabinet the front hatch and feeding hatch could not be made because they were not selected at the time 32 Chapter 7 Discussion 7 Discussion This chapter will explain the discussions of both the thesis process and theoretical framework and the result In the thesis process and theoretical framework reflections on the development process and method used will be presented The discussion about the fulfillment of specifications and final design will be discussed in the result 7 1 Thesis process and Theoretical framework The product development procedure outlined in this thesis follows the design methodologies including establishing the requirements specification identifying and expressing the functions generating solution proposals and organizing alternatives synthesis of concepts evaluating with respect to selection criteria and refined selected processes This approach was used as a guideline and timeframe for the thesis The time plan of the process was divided into four phases to ensure that the thesis works in good progress and on the right track as it proceeds from stage to stage In order to move on to the next phase the results should have met and fulfill the requireme
81. y changing the lifting hatch to a normal swing hatch that opens downward The decision not only solves the feeding hatch problem but also simplifies the space problem which is very tight inside the machine 5 2 2 Cooling system In the final product the cooling system is placed in the back of the instrument next to the electronic storage cabinet The drawing from the supplier indicates that if the cooling system is positioned in the back the air inlet and outlet will be placed on the backside of the equipment as well A ventilation problem might occur because the machine will be located close to the wall where there is restricted air flow An alternative solution was to place the cooling system on the side of the machine The only concern with this was the gap above the cooling system will be really tight because during the analysis the X ray components are moving to the left ends and right ends of the instrument The problems were solved when a new model of heat exchanger was discovered which is very thin but longer The decision was to put it on the top of the machine Even though the total height of the machine will be increased but when considering the advantage of having the air inlet and outlet on the top of the machine this solution becomes the most suitable choice The space at the back of the equipment can be used to install the water tank and pump because it is easier for maintenance when the water tank is separate from heat exchanger for in

Concept development of field analysis equipment for mining and

Contents

Download Pdf Manuals

Related Search

Related Contents