Developing a drill boom attachment to extract iron ore in a ...

DevelopingadrillboomattachmenttoextractironoreinanewminingsystemUtvecklingavettborrbalksfästeförbrytningavjärnmalmiettnyttgruvbrytningssystem

NiklasBerntsson

FacultyofHealth,ScienceandTechnologyDegreeProjectforBachelorofScienceinEngineering,MechanicalEngineering22,5hpSupervisor:KentEvermarkExaminer:AndersBielJune3,2021

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Abstract

The modern product development technique led this bachelor thesis forward withstructure and finesse by using the Double Diamond theory. The bachelor thesis wascarriedoutincollaborationwithLKABandNECABwiththeaimofdevelopanddesignatwo-partedmechanicalattachmentfortheirnewminingsystem.Theattachmentshouldsupportadrillrigandenablethedrilltotiltandalsotransferthedrillrigalongitsdrillingdirection. The attachment will be implemented into their new mining method withpurposetoincreasethesafetyandreducethecosttoextractironore.

Aprestudywasdone to reduce timedesigninganddimensioning the finalproductbyanalyzingthemechanicsof theattachment.Compendiumsthatanalyzethemechanicaldesignof theproducthasalsobeenused in theprestudy.Theprestudyaddressed thesafetyaspectbyfollowingtheEuropeanParliamentsdirective2006/42/EC.

Thefinaldesignwasaconceptthatinvolvedahydrauliccylindertotiltthedrillandasetofrackandpiniontoachievethelinearmovementofthedrill.Therackandpinionarepoweredbyahydraulicmotorwithaplanetarygearbox.Togenerateenoughtorquetoovercomethetorqueneeded,twosetsofplanetarygearboxeswithbelongingrackandpinionareusedoneachsideofthedrillboom.Asledgeisusedtosupportthedrillboomthatisslidingonthesledge.Toreducethefrictionbetweenthetwo,slidebushingsaremountedtothesledge.

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III

Sammanfattning

Modernproduktutveckling leddedennakandidatuppsats framåtmedgodstrukturochfiness genom att använda Double Diamond teorin. Denna kandidatuppsats utfördes isamarbetemedLKABochNECABmedmåletattutvecklaetttvådelatmekanisktfästetillderasnyagruvbrytningsmetod.Fästetskastödjaettborraggregatochkunnamöjliggöraborrenatttiltaochävenmöjliggöraenförflyttningavborraggregatetlängsborriktningen.Fästet kommer att implementeras i deras nyametod för gruvbrytningmed syftet attsäkerställa en högre säkerhet vid borrningenmen även attminska kostnaden för attutvinnajärnmalmen.

Enförstudiegenomfördesgenomattanalyseramekanikenavfästet,dettaminskadetidenatt konstruera och dimensionera den slutliga produkten. Kompendier i konstruktivutformning av en produkt har även studerats i förstudien. Förstudien lyfte ävensäkerheten i en produkt genom att följa Europaparlamentets maskindirektiv2006/42/EC.

Denslutligakonstruktionenvarettkonceptinnehållandeenhydraulcylinderförattstyralutningenavborrenochenuppsättningavkuggstångmeddrevpåsidanavborrbalkensomsköterförflyttningenavborren.Enhydraulmotormedenpåkoppladplanetväxelstyrdrivningen av drevet. För att klara av momentbehovet som krävs så har dubblauppsättningaravplanetväxlarmedtillhörandekuggstångochdrevanväntspåvarderasidaavborrbalken.Enslädeanvändesförattstödjahelaborrbalkensomsedangliderpåsläden. För attminska friktionenmellan de två användes en uppsättning av glidlagermonteradepåsläden.

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TableofContent

1Introduction...................................................................................................................................................................1

1.1Background..................................................................................................................................................................................1

1.2Purposeandaims......................................................................................................................................................................2

1.3Limitations....................................................................................................................................................................................2

1.4LKABandNECAB.......................................................................................................................................................................3

2Methodandtheory......................................................................................................................................................4

2.1Projectplan..................................................................................................................................................................................6 2.1.1Projectmodel.....................................................................................................................................................................6 2.1.2Riskassessment................................................................................................................................................................6

2.2Productspecification................................................................................................................................................................7 2.2.1Prestudy...............................................................................................................................................................................8 2.2.2CriteriamatrixandQFD..............................................................................................................................................10

2.3Concept.........................................................................................................................................................................................13 2.3.1Conceptgeneration.......................................................................................................................................................13 2.3.2Conceptselection...........................................................................................................................................................15

2.4Designandstructuralverification....................................................................................................................................19

3Result.............................................................................................................................................................................20

3.1Projectplan................................................................................................................................................................................20 3.1.1WBS&Gantt.....................................................................................................................................................................20 3.1.2Riskassessment..............................................................................................................................................................21

3.2Productspecification..............................................................................................................................................................22 3.2.1Prestudy.............................................................................................................................................................................22 3.2.2Criteriamatrix.................................................................................................................................................................23 3.2.3QFD.......................................................................................................................................................................................25

3.3Conceptgeneration.................................................................................................................................................................26 3.3.1Benchmarking..................................................................................................................................................................26 3.3.2Brainstorming..................................................................................................................................................................26

3.4Conceptselection.....................................................................................................................................................................27 3.4.1PahlandBeitz..................................................................................................................................................................27 3.4.2Pugh.....................................................................................................................................................................................28 3.4.3Explanationofconcepts..............................................................................................................................................30 3.4.4Kesselring..........................................................................................................................................................................33 3.4.5FMEA....................................................................................................................................................................................34

3.5Designandstructuralverification....................................................................................................................................35 3.5.1Design..................................................................................................................................................................................37 3.5.2Structuralverification..................................................................................................................................................39

4Discussion.....................................................................................................................................................................45

5Conclusion....................................................................................................................................................................47

5.1Futurework...............................................................................................................................................................................47

VI

References.......................................................................................................................................................................48

Appendix..........................................................................................................................................................................50

AppendixA,WBS.............................................................................................................................................................................50

AppendixB,Gantt...........................................................................................................................................................................51

AppendixC,Modeltree.................................................................................................................................................................52

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1Introduction

1.1Background

Luossavaara-KiirunavaaraAktiebolag(LKAB)isaminingcompanythatextractironoremainly from Kiruna, Malmberget and Svappavaara which is located in the north ofSweden.Theyarecurrentlydevelopinganewminingsystemthatrequiresamachinerywith several platformswith differentmining equipment attached to it (machinery toprovideproductionfromtheraiseboredshaft),seeFigure1.Theplatformsaregoingtobeloweredintoashaftwithadiameteron4,5metersandadepthupto250metersfromitsraiselevel(areaforthetransportroutes).Thisshaftshallfollowthedipoftheorebodysotheshaftcannotalwaysbedrilledvertically,morelikely,somewherebetween0-30°fromitsverticalaxis,seeFigure1b.Figure1isalsoshowingthefictionalholesdrilledinits30°angle.

Therewillbeadrillrigattachedtothemachineryatthelowestplatform.Thisdrillneedsanattachmentbetweenthedrillboomandtheplatform.Theattachmentshallfitbetweentheslewdriveandthedrillboom,therelevantcomponentsareviewedanddescribedinFigure1a.Thedrillboomneedstobeabletorotate,translateandtiltsoitcanbeadjustedtotheshaft.Therotationwillbepoweredwiththeslewdrive,butthetranslationandtiltareyetnotdetermined.

Figure1:a)Principalsketchoverthemachinerywhenshaftdrilledvertically,b)Shaftdrilledwith30°inclination

a) b)

Slewdrive

Drill

Drillboom

30°

Fictionaldrillholes

Lowestplatform

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1.2Purposeandaims

Thepurposewiththenewminingsystemistomaketheminingoperationmoreefficientand secure when the drilling depth increases. The problem when mining deeper isincreasedstressconcentrationintheorebodyandonthemine’sinfrastructure.Withthisnewminingsystemtogetherwithinnovativedestressingtechniques,theminelayoutwillbesimplerwithlessdevelopmenttunnelsandfewerpeopleinriskareas.Thisincreasesthesafetyandalsominimizesthecosttoextracttheironore.

Thepurposeforthetranslationandrotationofthedrillboomistoadjustthedrilltothecorrectpositionaroundtheshaftaxisofrotation.Thedrillboommustbeadjustedtoapositionasclosetotheshaftwallaspossible.Thisbecausethatthedrillsupportmustbeplacednearthewallstoincreasethestabilitywhendrilling.

Thepurposeofthetiltistomanagedrillingindifferentangles,thisgivesflexibilityinthedrillpatternandisnecessaryduetothepotentialchangeoftheorebodyinclinationandapplicationofdifferentblastdesigns.

Theaim for thisproject is todesignanewdrillboomattachment for thenewdrillingmachineusingmodernproductdevelopmenttechniques.Thefinalresultwillbeaconceptthatwillbereadyformanufacturing.Withintheseproductdevelopmenttechniques,thefinalconceptshallpossessperformance,includestrengthanalysisandincludehydraulicsystemsfortiltandtranslationofthedrillboom.Theattachmentshallhandlealoadupto5tons.

1.3Limitations

Thedrillboomattachmentshallallowthedrill torotate, translateandtilt.Thismeanstheremustbesomekindofpowersourcethatcanperformtheseactions.Indiscussionwiththecompany,thepowersourcewillbedimensionedandchosentothefinaldesign.Thescopeofthisprojectextendstothehydrauliccontrolsystem,wherethevalvepackageanditsassociatedcomponentslikecontrol-,shutoff-,pressurereliefvalves,hoses,filtersandmainpowersourcewillnotbedimensionedinthisthesis.Thehydraulicpressureissetto200bar.No2Ddrawingswillbemade.

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1.4LKABandNECAB

LKAB and NECAB (North Engineering Consulting Aktiebolag) are the projectscommissioners.LKAB isownedby theSwedishstateand isan internationalhigh-techminingandmineralcompanythatextractandrefineNorrbottensuniqueironorefortheglobal steel market. NECAB is a consulting company that provides companies withexpertiseinmechanicalengineeringfortheindustryandthustheminesownedbyLKAB.LKABistheowneroftheproject,butNECABhasbeenassignedthetasktodesignanddevelopthenewmachine.ThisbachelorthesisisconductedatLKAB,butthesupervisorisworkingatNECABandprovidestechnicalinformationregardingtheproduct.

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2Methodandtheory

Modernproductdevelopmentworkisalmostalwaysconductedinprojectformandthisthesisisnoexception.Aprojectisdefinedasataskwithdeterminedanddelimitedgoals,aprocess linewithspecificdeadlinesandanassignedorganizationwithadeterminedbudget,thebudgetinthisprojectiscalculatedintime[1].

ThisprojecthasitsbasearoundtheDoubleDiamondtheorythatisamappedwayforadesigner to organize their processes through the product development session. TheDouble Diamond includes two diamonds with four distinct phases; Discover, Define,DevelopandDeliver[2],seeFigure2.

Figure2:Overviewofthedoublediamondmap[3]

Inthediscoveryphase,itissupposedtogetaninsighttotheproblem,placetheprobleminacontext,doresearchinthespecificareaofinterest,createthefirstinspirationandtodosomedrawingstoclarifythetask.Thisphaseisbasedonthedivergentthoughtwhichbasicallyisthinkinginalldirectionstogenerateabroadbasebeforenarrowingdownthetask. In thisphase theprojectplanning isdonewhereaprojectplan is submittedthatclarifiestheprojectinmoredetail[2].

During the define phase, the purpose is to be a little more specific, here there isconvergent thinking, the opposite of divergent thinking,where the idea is to find thespecificsolutiontotheproblem.Intheendofthisphasetheproductspecificationwithallrequirementsandrequestshallbestatedsothenextwideningphasecouldstartagain,whichisthedevelopphase[2].

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The idea during the develop phase is to generate potential solution for the specificproblem. Creativemethods like brainstorming and visualization are used to generatetheseideasandtocreatebasicsketches.Allideasandthoughtsarewelcomedtowideningtheperspectivewherenocriticismisallowed[2].

Inthedeliverphasethefinalconceptshallbechosenbasedontheproductspecificationthatwas done in the define phase. Final 3D sketches and possible prototypeswill becreated[2].

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2.1Projectplan

Intheearlystageof theproject,aprojectplanwasdefinedwithpurposetoworkasagoverningdocumentforhowtheprojectwillbeproceeded.Theprojectplandefinesthetasktobesolved,timeframes,resourcesandtheinvolvedpeople[4].

2.1.1Projectmodel

Theprojectmodeldescribeshow theprojectwill beperformed,whichphaseswill beexecutedand importantdeadlines. Itmightbe important and sometimesnecessary toiteratethephasesinvolved,inmodernproductdevelopment,thisapproachiscommontouse[4].

To create a systematic structure for the parts involved in the project, a WBS (WorkBreakdownStructure)wascreated.AWBSisahierarchicalstructureovertheprojectsallprocesses,theadvantageofthismethodisthattheprojectreceivesanoverviewofallthetaskstobeperformed.TostructuretheprojectevenfurtheraGanttschedulewasappliedtogetherwiththeWBScharttodefinetheprocessestimeframes.WiththeGanttscheduletheprojectnowhasatimeaxistofollow[4].

2.1.2Riskassessment

TheriskassessmentisbasedontheprocessoftheprojectandisdoneasaprocessFMEA(FailureModesandEffectsAnalysis).TheFMEAusestheprobability(P)andconsequence(C)fortheselectedriskandtheriskfactor(PxC)shallbeminimized,seeFigure3.Therisksarestatedwithadescriptionoftheriskwithitsassociatedconsequence.Asolutionis suggested for the selected risk and a new risk analysis is calculated based on thissolution,iftheriskfactorislower,thesolutionwassuccessful[4].

Figure3:TemplatefortheprocessFMEA

FMEA Process X Function/Construction

Issuer

Edition

Consequence Consequence(C:1-5) (C:1-5)

4

3

2

1

SolutionNewriskanalysis

ProbabilityPxC

ProbabilityPxC

(P:1-5) (P:1-5)ID Riskarea Descriptionoftherisk Consequenceoftherisk

RiskanalysisCause

Designation Page

Project/Object Date

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2.2Productspecification

Withthegivenbackgroundandaninitialideaofwhatthefinalproductwilllooklike,thenextstepistocollectnecessarydatatocompletethejobdescriptionfromthecompany.Theproduct specificationwill describewhatwill be achieved and itwill be a floatingdocument that is developed and updated during the process. The purpose with theproduct specification is to concretize the problem and to ensure that all thecommissionersandaspectsaretakenintoaccount[5].

Awellperformedproductspecification leads todecreaseddevelopment timeandcostthankstoearlierandfewerchangeswithanincreasedquality,thisalsoleadstoamorecompetitiveproduct[5].

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2.2.1Prestudy

At least twopoweredmotorsshallbehandling the tiltand the translation.For the tiltfunction, a critical load occurs when the drill is tilted to the maximum angle. Themaximum moment that the drill assembly exert to the pivot point are calculated inequation1,theassociatedacronymsareexplainedinTable1.InFigure4,theFBD(FreeBodyDiagram)isshown.

!𝑀! = 0;𝑀! = sin(∅) ∙ 𝑔(𝑚" ∙ ℎ" +𝑚# ∙ ℎ#) (1)

Figure4:FBDshowingexertingmoments

Table1:Acronymsformoment-andfeed-forcecalculations

Description Acronym Unit

Minimummomenttotilt M t NmTiltangle ∅ Deg

Gravitationalconstant g m/s2

Massofdrill m d kgHeightfromCoGtorotationalpoint h d m

Massofattachment m a kgHeightfromCoGtorotationalpoint h a m

Feed-force F NCoefficientoffriction μ -

⌀

ha

hd

md⋅g

ma⋅g

Mt

y

x

9

Theneededfeed-forceiscalculatedinequation2andistheforcerequiredtoovercomegravityandfrictionbetweenthedrillboomandtheattachment.Thefeed-forceenablesthedrillboomtotranslatealongthedrillingdirection(x-direction).FfisthefrictionforceandFGisthegravitationalforceofthedrill,F1andF2arethegravitationalcomponents.Figure5showstheFBDfortheforcesexertedonthebody.

Theareaofuseforthisattachmentisinaminewheretheydrillforironore.Whendrilling,gases can arise from themountain and then become a potential explosion hazard. Ifelectrical components shall be used, then it is recommended to have an ATEX(Atmosphére Explosible) classification to the components. An ATEX classification is aclassificationtoelectricalcomponentsthatclarifiesthatthecomponentdoesnotcauseasparkfromtheelectricalcomponenttostarttheexplosion.Tworegulationsarticles,onefromArbetsmiljöverketAFS2010:1[6]andonefromEuropeanParliament2014/34/EU[7]havebeentakenintoaccountwhendevelopingthisproduct.

Sincethisisaproductdevelopmentthesiswiththemaingoaltogenerateaconceptthatis ready formanufacturing, a prestudy regarding design andmanufacturing has beenperformed. Safety will always be an important factor when designing products andbecausetheattachmentcanberegardedasaliftingaccessory,EUdirective2006/42/EC[8]comeswellinhandtomakesurethesafetyisfollowed.TheEUdirectivetellsushowtodesignaproductregardingtowhattheproductis.Thedefinitionofaliftingaccessoryaccordingtothedirectiveobey:

!𝐹$ = 0; 𝐹 = 𝐹% + 𝐹& = (𝑚" +𝑚#) ∙ 𝑔(cos(∅) ∙ 𝜇 + sin(∅)) (2)

Figure5:FBDshowingforcesexertedonthebody

F

FN

FGF1

F2

Ff

⌀

y

x

10

“´liftingaccessory´meansacomponentorequipmentnotattachedtotheliftingmachinery,allowingtheloadtobeheld,whichisplacedbetweenthemachineryandtheloadorontheloaditself,orwhichisintended to constitute an integral part of the load and which isindependently placed on the marked;” (The European ParliamentandtheCounciloftheEuropeanUnion)[8].

Toavoidstructuralfailure,agoodunderstandingformechanicaldesignisnecessary.Aprestudy is furtherdonewithtwocompendiumsexplainingwhat to thinkaboutwhendesigning components. Sundström et al. [9] andHelmer et al. [10] haswritten thesecompendiums.

2.2.2CriteriamatrixandQFD

The product specification contains the product requirements and requests that arecollected by all stakeholders. The criterions have its base in the Olsson matrix thatdescribestheproductsdifferentlifecyclephasesanditsaspects,seeTable2. TogetherwiththeOlssonmatrixthecriterionsweresortedintoatablewherealltherequirementsandrequestswerestatedwithitsbelongingcellbasedontheOlssonmatrix.Thecriterionswerealsocategorizedifitwasafunctiontotheproductoralimitation[5].

Together with the product specification, a QFD (Quality Function Deployment) wascreatedtogenerateamorevisualizedenvironment,Figure6showsaprincipaloverviewof theQFD.TheQFDhelps topresent the relationshipbetween the criterionsand thefunctionsandalsocreateatargetvaluetoguidetheproducttomakeitfulfilltheproductspecification[11].

AspectsLifecyclephase

Development 1.1 1.2 1.3 1.4Manufacturing 2.1 2.2 2.3 2.4

Sales 3.1 3.2 3.3 3.4Use 4.1 4.2 4.3 4.4

Elimination 5.1 5.2 5.3 5.4

Process Environment Human Finance

Table2:Olssonmatrix

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Figure6:QFD,anoverviewofthequalityhouse

Technicalscore

Productattributes

Priorities

Technicaldifficulty

Targetvalues

Voiceofthecustom

er

Relationshipmatrix

How?

Interactionmatrix

What?

1 2

3

4

6

5

12

ThefollowingstepbystepguidedescribestheQFDhouseanditfollowsthenumberedstructurefromFigure6[11].

Step1.Usetheproductspecificationtostateallthecriterionsagainanduseprioritiestoprioritize the most valued criterion. The requirements receive a score of 6 and therequestsreceiveascorefrom1to5dependingonitspriority.

Step2.Definehowthecriterionswillbefulfilled.Inthisstage,itistimetotransferthecriterionstoproductattributes,theproductattributesareadescriptionoftheproductsfunctionsintechnicalterms.Theattributesshallbemeasurablesothataverificationlateroncanverifythattheproducthasfulfilledthecriterions.

Step 3. The relations between the criterions and the attributes are now valuedwith,Strong,averageorweakrelationwith9,3,or1pointrespectively.

Step4.Oftentheattributesareincorrelationwitheachotherandtoenhanceoneattributemightimpairanotherattribute.Inthisstepthecorrelationbetweentheattributesissetupwith;Positivecorrelation(+),negativecorrelation(-)orblankwhennocorrelationoccurs.

Step5.Thisisanimportantstepinproductplanningtoestablishthepreliminarytargetsfortheproductattributes.Thesevaluesareonlypreliminaryandmightbechangedinalaterstage.Thetargetvaluecomesfromtheresearchdoneintheplanningstageandwiththecompany’sjobdescription.

Step6.Todeterminethetechnicalscoreoftherelationshipmatrixisbymultiplyingthecriterions priority to the attribute’s relation, which is described in equation 3. Thepurposetocalculatethescoreistocreatealargerunderstandingofwhichattributethatgivesthelargestoutcomeinafutureconcept.Itisalsoimportantinstep6todeterminethetechnicaldifficultiesonhowharditistoreachthetargetvalue,thedifficultlyisvaluedinascalefrom1to5.

𝑇𝑒𝑐ℎ𝑛𝑖𝑐𝑎𝑙𝑠𝑐𝑜𝑟𝑒 =!𝑤𝑒𝑖𝑔ℎ𝑡 ∙ 𝑎𝑡𝑡𝑟𝑖𝑏𝑢𝑡𝑒𝑠𝑟𝑒𝑙𝑎𝑡𝑖𝑜𝑛 (3)

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2.3Concept

Withtheproductspecificationdetermined,generatingsolutionsfortheproductisnowpossible. As an initial step of the concept phase, the product will be divided into itsdifferentsubfunctions.Theideaistogenerateasmanysolutionsaspossible,thatlateroncan be chosen among. With this structural way, it ensures that the entire space ofsolutionshavebeenmappedandthusnosolutionswillbemissed[5].

Theconceptselectionphasewillincludeseveralselectionmethodstoensurethatthebestconceptisselected.Itisusefultohaveinmindthattheselectionprocessisnotthatpreciseduetopersonalinterferencetotheconcepts.Toreducethisfactoroferrormanydifferentselection stages is executed.Another thing tohave inmind is that the concept canbealmostidenticaltoeachotherandmaybedifferjustapointorso.Thisphenomenonisalsoconsideredwhenselectingconcepts[5].

2.3.1Conceptgeneration

Intheearlyphaseoftheproject, it is importanttoentertheconceptgenerationphasewithanopenmindforeverykindofinformation,itisnotausefulthingtorejectideasinthisstage.Everyideaandconceptthatwillbecreatedherewill laterbeevaluatedandexcludedintheconceptselectionphase[5].

To generate concepts, modern product development theory is used. This theorycategorizestheconceptgenerationsessionsintotwocategories,creativeandsystematic.Methods like benchmarking and brainstorming is used in the creative category.Benchmarking,where it is important tobecreativeandsearching forother industrieswheretherearesimilaritiesintheproducttobedeveloped.Brainstorming,wherealltheinputs and information from the benchmarking session shall be implemented in theproduct.Forthesystematiccategory,thegoalistowidentheproductandtostartdividingtheproduct into its sub functions.To search for solutions to the sub functions and tocombinethesesubsolutionsinasystematicstructuralwayisalsocategorizedintothesystematiccategory[5].

2.3.1.aBenchmarking

Searchingforinspirationfromcompetitorsorwithindifferentindustries,newideasandsolutions arises through a benchmarking session. It is a well-known fact that it isimportanttobeawareofnewtechnologiesandsolutionswithintheselectedindustry,thiscreatesalargerperspectivetowhattheoutsideworldsdemands.Itisalsoimportanttoknow how the product will perform towards the competitors. Benchmarking is astructuralwayoffindingopportunitiesforimprovement,thebaseideaistometiculouscompererelevant informationatanother industryandtobenefit fromthecomparison[11].

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2.3.1.bSubfunctions

The productwas later divided into its sub functions, this gives an easier and amoremanageableconceptgenerationsession.Thegoalistogeneratesolutionsontheselectedsubfunctionandnottolookatasolutionforthewholeproductatonce,thismethodgivesa more innovational strategical procedure of generating concept. In Table 3, themorphologic matrix template is shown with a polygon train that combines the subsolutionsintoacompleteconcept.Totalamountofconceptgeneratedarenumberofsubsolutionstothepowerofnumberofsubfunctions.Meaning intheexample inTable3there are: 𝑁𝑢𝑚𝑏𝑒𝑟𝑜𝑓𝑐𝑜𝑛𝑐𝑒𝑝𝑡𝑠 = 4' = 1024concepts. These concepts are notnecessarily applicable to the criterions set up in the product specification, but theconceptsarenotevaluatedinthissession,theconceptswillbeevaluatedlateronintheconceptselectionprocess[5].

2.3.1.cBrainstorming

As an opening session to find solutions to the sub functions several brainstormingsessionsareperformedbothwithhelp fromclassmatesandsupervisors.Thiscreativemethodofgeneratingsolutionsiswidelyusedintheindustryandisasessionthatgatherspeoplewithdifferentqualifications.Brainstorminghasunfortunatelybecomeasynonymasageneralwayofjustcomingupwithideas,butthismethodiswidelydevelopedandadefined process with specific rules. The brainstorming session begins by gathering agroupof peoplewhere one is the leader that clearly explains the initial problem.Thegroupshallwithoutjudgingtheemergedresultgenerateasmanyideasaspossible,thegroupshallalsocomplywiththefollowingfourspecificrules[5].

• Nocriticismisallowed• Quantitybeforequality• Gobeyondtheordinaryandgladlyusewildideas• Usetheideasasbuildingblockstobuildandcombinenewideas

SubfunctionsFunction1Part1 Solution1 Solution2 Solution3 Solution4

Cell# 1.1 1.2 1.3 1.4Part2 Solution5 Solution6 Solution7 Solution8

Cell# 2.1 2.2 2.3 2.4

Function2Part3 Solution9 Solution10 Solution11 Solution12



Cell# 5.1 5.2 5.3 5.4

Subsolutions

Table3:Thetemplateofthemorphologicmatrix

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2.3.2Conceptselection

2.3.2.aUlrichandEppinger

TheconceptselectionprocessisfollowedafterUlrichandEppinger´sstrategicalmethod.UlrichandEppinger´sevaluationprocesscanbeseeninFigure7wheretheprocessaftersearchingforsolutionsisasfollowed.

1. EvaluateandeliminateallthebadsolutionswithPahlandBeitzmatrix2. UseofPugh´srelativedecisionmatrix3. UseofKesselring´scriteriamatrix

2.3.2.bPahlandBeitz

Toeliminateallbadsolution,aneliminationmatrixfromPahlandBeitzissetupwithallthegeneratedconcepts.Theseconceptsaretobeevaluatedandeliminatedbasedtothefollowingcriterions.Thecriterionsare:

• Doestheconceptsolvethemainfunction?• Doestheconceptfulfillallrequirements?• Istheconceptrealizable?• Istheconceptsafeandergonomic?• Istheconceptsuitableforthecompany?• Isthereenoughinformationavailable?

Thematrix template isseen inFigure8.Byevaluatingall thegeneratedconceptswiththesecriterions,theconceptsbecomefewerinthenextmoredetailedevaluationmethod[5].

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

p

Searchforsolution Evaluationandeliminationofbadsolutions

Relativedecisionmatrix

Criterionweightmethod

Figure7:UlrichandEppingerevaluationprocess

16

2.3.2.cPugh

TheconceptsthatpassedtheeliminationmatrixmovesontoPugh´smatrixwheretheconceptsareevaluatedinmoredetailandtheconceptsaresetagainsteachother.Theproduct specification is used as a ground for the evaluation and also itsweighting tocreateamoreempathizedselectionforthosecriterionsthatareofmoreimportance.Oneoftheconceptswassetasagroundreference, iftheotherconceptwasbetterinthosecriteriatheconceptgota+sign,ifitwasworse,a–signandifitwasthesame,a0,seetemplate inFigure9.Thesevalueswere calculated toget anet scoreand then lateraranking,wheretheconceptwiththehighestnetvaluewasrankedas1.Adecisionlateronwasdecidediftheconceptshouldbefurtherdevelopedornot[5].

Weight x.x[ref] x.x x.x x.x x.x

0NetvalueRank

Furtherdevelopment

Criterions Concept#

Sum+Sum0Sum-

Figure9:Pugh´srelativedecisionmatrix

Comment Decision12345

Function1 Eliminationcriteria(+)Yes(-)No(?)Moreinforequired(!)Checkspecification

Concept#

Solvesmainfunction

Fullfillsallcriterions

Realizable

Safeandergonom

ic

Suitableforthecompany

(-)Notpassed(?)Gathermoreinformation(!)Checkspecification

Decision(+)Passes

Enoughinfo

Figure8:PahlandBeitzeliminationmatrix

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2.3.2.dKesselring

TheconceptsthatweredecidedtobefurtherdevelopedinPugh´srelativedecisionmatrixwas then evaluated once more in Kesselring´s criteria matrix. This because of itsimportance to have inmind that the results from thesemethods are not precise andperfect.Theresultscandifferinonlyoneortwopointsandbythatmeaningtheresultarealmost identical. In Kesselring´s criteria matrix the criterions from the productspecificationthataremeasurablewillbethecriteriontheseconceptsareevaluatedat.Theconceptgetsavaluefrom1-10onhowwellitfulfillsthecriteria,togetherwiththeweightonthecriteria,theconceptgetsascore,(WxP)thatlateronissummarizedtoatotalscore,seetemplateinFigure10.Indiscussionwiththecompanyafinalconceptisselectedtobedesignedtoitsfinishedmanufacturableproduct[5].

Foraproductthatconsistsofmanydifferentfunctionsandcomponents,itmaybewiseandmany times necessary to repeat and iterate both the concept generation and theconcept selection sessions. It may also be wise to use these sessions on individuallyfunctions/components to have an evenmore specific selection on the concepts.Withthese iterative methods, it will most likely result in many concept generation andevaluationsessions[5].

Figure10:Kesselring´scriteriamatrix

Criteria Weight Guideline Points WxP Comment Points WxP Comment

0 0

0

0

Conceptx

0

0

0

0

0

0

Projectdescription Conceptx

Drillboomattachment

18

2.3.2.eFMEA

Whentheconceptisselected,afunctionFMEAwascreated,seetemplateinFigure11.ThepurposewiththeFMEAistoanalyzeandlocateproblemsorfailuresthatcanappearforthe product and analyze the consequence for this failure. In a FMEA, there are threeaspectstorelatetoandthatis:S(severity),O(occurrence)andD(detection).Alltheseaspectsareevaluatedfrom1to10andbymultiplyingthese,theSODnumberiscreated.TheSODnumberpresentsthehighestpotentialfailurethatcanoccurandbyapplyinganactiontothatfailure,theSODnumberissupposedtodecrease[5].

FMEA Process X

date

Project/Object

Designation

CauseConsequencePart/Process

05 0

04 0

0

0

3 0

0

0

2

SOD

1 0

Done-Newfailureanalysis

Potentialfailure S O D SOD S O DID

FailureCharacteristics FailureanalysisRecommendedactionFunction

Function/Construction

Issuer Date

Edition Page

Figure11:FunctionalFMEAtemplate

19

2.4Designandstructuralverification

Whenthefinalconceptisdeterminedandacceptedbythecompanythenextphaseistomake the concept ready for manufacturing. The first thing that was created was apreliminary model tree over the constituent parts involved in the concept. This treedefinesassemblies,custompartsandpurchasedparts.Withthetreestructuredone,thedesignwill passover to3DCAD (ComputerAidedDesign) environmentwhereall themodellingisdonewithCreoParametric5.0.Thisstageisthetransitionbetweenaconceptandaproductreadyformanufacturing.

Simplerverificationmethodsforforceandmomentswillbecalculatedbyhand.WithFEM(Finite Element Method) the structural parts will be analyzed and dimensioned, thesimulationsformovementwillbedoneinCREOMechanism.

20

3Result

3.1Projectplan

Thisprojectisperformedbetweenweek3andweek23andis includingfourdifferentphaseswiththefollowingintendedweeklyplanningandinvolveddeadlines.

1. Planning(w.3–w.7)• Submissionprojectplan–29January• Presentprojectplan–2February• Gate1,productspecification–15February

2. Concept(w.8–w.14)

• Submissionmethod&theory–19Mars• Haft–timepresentation–30Mars• Gate2,Conceptselection–31Mars

3. Design(w.15–w.18)

• CADstop–5May

4. Closure(w.19–w.23)• Submissionreportforopposition–17May• Finalpresentation–24May• Submissionwrittenopposition–27May• Submissionfinalreport–7June

3.1.1WBS&Gantt

TheWBScanbeseeninAppendixAandgeneratedavisuallyviewovertheprojectsallinvolvedphases.TogetherwiththeWBS,thestateddeadlinesandtheweeklyplanning,aGanttschedulewascreatedandgeneratedanoverviewofthefullplanning,seeAppendixBforGanttschedule.

21

3.1.2Riskassessment

Figure12showstheprocessFMEAthatcontainsalltherisksovertheprojectandhowtosolveorminimizethestatedrisk.Therearetworiskswhichstoodout:

Theplanningisnotfollowed:Thisriskismajorlycausedbynotdoingwhatissupposedandpostponethethingsplanned.Tosolvethisrisk,adetailedplanningwithdeadlinesandfollow-upsisplanned.Afterapplyingthissolution,theriskfactordrasticallydroppedwhichmeantthatthesolutionwassuccessful.

My hardware crashes: This risk is difficult to foresee, but the solution makes a largedifferenceintheriskassessment.Thesolutionistocreatebackupsdailytoanexternalharddrivetomakesurenolargerpartsofthepreviousworkislost.

FMEA Process X Function/Construction

IssuerNiklasBerntsson

Edition1

Consequence Consequence

(C:1-5) (C:1-5)

Date2021-01-22

Page1

Riskarea

Communication

Planning

Descriptionoftherisk

Thefinalproductdoesn´tfulfilltherequirements

Theplanningisnotfollowed

Project/ObjectBachelorthesis

Drillboomattachment

Designation

2

2

1 38 2 63 3Planning CreateaflexibleplanningforchangeLesstimeforthisprojectTheparallelcourseexceedsitsplannedtime

1 27 2 84 2Planning FollowtheplanningTheparallelcoursefallsbehindIspendtomanyhoursonthethesis

1 26 2 84Planning 2FollowtheplanningTheproductgetstooexpensiveIspendtomanyhoursonthethesis

2 45 4 82

Resources

Health

2

2Consultationwithcompany

Iloseallmypreviouswork

Thesubmissionswillnotbecompleted

Myhardwarecrashes

Igetsickorinjured

2 4

3 3Communication Thecompanyneglectme

Thesubmissionswillnotbecompleted

Theprojectstandstill

4 5 102

34

2

3 1

1

Createbackupsdaily

6

12

Goodconnectionwiththecompany 3

Newriskanalysis

PxCID

Riskanalysis

CauseConsequenceoftherisk Probability

(P:1-5)

4 4

Probability

(P:1-5)

1

Solution

Thecustomerdoesn´tbuythesolution

PxC

1 4 8 DoublechecktherequirementsBadcommunication

NotdoingwhatI'msupposed

Badcommunication

Badcomputer

Illness,defected,Covid

Ihavehighdemandsonmyself

Ihavehighdemandsonmyself

Badplanningfromcourseadmin

3

3Deadlines,follow-ups,meetings

Figure12:Resultoftheriskassessment

22


Theproductspecificationwaswellusedintheproject,bothintheconceptphasebutalsointhedesignphase.Thisgoverningdocumentwastheguaranteethattheprojectfulfilledallrequirementsfromthecompany.Aftertheapprovaloftheproductspecificationfromthecompany,theguaranteethatnobodycouldcomelateronandsaythatthisshouldalsobeincludedintheproductwasguaranteed.

3.2.1Prestudy

Moment around point of rotation and feed-force were calculated based on valuescollectedfromthe3DmodelinCreo.

∅ = 30° 𝑔 = 9,82ms! 𝑚" = 5000kg ℎ" = 0,7m 𝑚# = 570kg ℎ# = 0,15m 𝜇 = 0,15

Momentcalculatedbasedonequation1fromtheprestudy:

𝑀! = sin(∅) ∙ 𝑔(𝑚" ∙ ℎ" +𝑚# ∙ ℎ#) = 17600Nm

Feed-forcecalculatedbasedonequation2fromtheprestudy:

𝐹 = 𝐹% + 𝐹& = (𝑚" +𝑚#) ∙ 𝑔(cos(∅) ∙ 𝜇 + sin(∅)) = 34450N

Arbetsmiljöverket[6]isstatingthatwiringharnessesasfaraspossibleshallbekeptfreefromdust and other substances that can encapsulatemoisture. This applies to all theelectricalcontrollersandsensorsused.Inthisproductthesensorswillbeintegratedinthecylindersandinthehydraulicmotor.AlltheelectricalcomponentsshouldneedanATEX classification according to directive 2014/34/EU [7]. The machine directive2006/42/eg[8]statestousesafetyfactorfor liftingdevicesat1,5,thissafetyfactorisusedinthisproductaswell,bothforshearstressandbendingstress.

23

3.2.2Criteriamatrix

Table4:Criteriamatrix

BelowfollowsanexplanationofeachcriterionfromthecriteriamatrixinTable4.

1. Adjustthetiltangle.Thetiltangleshallbewithin0and-30°togenerateamorefavorablemininggeometry.

2. Performatranslationofdrillboom.Thelinearmovementofthedrillboomshall

alwaysbepossibletoperformtowardstheshaftwallsregardlessofdrillangle.3. Staticallyhandlealoadof5tons.Thetotalweightthattheattachmentneedstobe

abletohandlestaticallyis5tons.Thedrillingmachineisequippedwithstingerswhosepurposeistostabilizethedrillwhendrillingthereforethestaticallyloadswillbeanalyzed.Therearesomeother loadswhenadjustingandpreparingthedrillbeforedrillingandthestrengthanalysisshallalsoanticipateandvalidatetheattachmentfortheseloads.

4. Handleawaterhose,D=70mm.Theattachmentneedstomakespaceforawater

hosewithdiameterof70mmthatisgoingtothedrill.Thehoseshallgothroughtheslewdriveandthusthroughtheattachment.

# Cell Requirement/Request Critera Function/Limitation

1 4.3 Requirement Adjustthedrillanglebetween0and-30° Function

2 4.3 Requirement Performatranslationofdrillboom Function

3 1.1 Requirement Staticallyhandlealoadof5tons Limitation

4 4.1 Requirement Handleawaterhose,D=70mm Function

5 4.1 Requirement Handle32hydraulichoses,D=20mm Function

6 1.1 Requirement FulfillEU´slawsandregulations Limitation

7 4.3 Requirement Highsafety Limitation

8 1.1 Request Lowweight Limitation

9 1.1 Request Compactandrobust Limitation

10 4.3 Request Hydraulicallyoperated Limitation

11 4.2 Request Enduredustanddirt Limitation

12 1.1 Request Lowcomplexity Function

24

5. Handle 32 hydraulic hoses, D=20mm. The attachment also needs to handle 32hydraulichoseswithadiameterof20mm.Asinrequirement4,thehosesmustgothroughtheslewdrive.

6. FulfillEU´slawsandregulation.Themachineshallworkinaminesotherearesome

regulations and laws to relate to. AFS 2010:1 and European Parliament2014/34/EUare two regulations to relate to.But also, themachinerydirective2006/42/EG

7. Highsafety.Theattachmentshallfocusonhighsafetyandavoiddowntimeforthe

producttogenerateaneffectivemining.8. Lowweight.Theweightshallbeaslowaspossible.

9. Compactandrobust.Theattachmentshallbeascompactandrobustaspossible

andcannotexceedtheinterfacetothemachineinheight.10. Hydraulicallyoperated.Sincetherearealreadyhydraulicsinthedrillingmachine,

itisrecommendedthattherestoftheattachmentalsoisoperatedwithhydraulics.11. Enduredustanddirt.Theattachment shallbeoperated inanenvironment that

contains high amounts of dust- and dirt particles, thus themechanisms of theattachmentneedtobeprotected.

12. Low complexity. The machine will need maintenance under its operated time,

because of the maintenance, the attachment shall be of low complexity withinterchangeableparts.

25

3.2.3QFD

InFigure13,theresultfromtheQFDisshown.Thethreeattributeswiththehighesttechnicalityscoreare,Strength,StaticloadandUnitweight.

Figure13:QFD

QFD:QualityFunctionDeployment

+-

931

⬈◇⬊

Column# 1 2 3 4 5 6 7 8 9 10 11 12 13CategoryTarget ◇ ◇ ◇ ⬊ ⬈ ◇ ⬊ ◇ ⬈ ⬈ ⬊ ◇

84 84 30 175 99 169 45 186 133 201 171 69 0

Difficulty 3 3 3 2 2 3 3 3 4 2 1 1

Targetvalue

0to-30deg

Toshaftw

all

360deg

Low

Height

Low

SF1.5

Reducestress

High

Low

Yes

7

8

9

10

3 9

3 3

3

3 9 3

Hydraulicallyoperated 3

9 3

3

3

93 9

3 1 3

31 3

1

9 9 9

9

1 1 1 1 3

1

3

9 3 9

3

3 9

Request

Row#

Weight

6

6

6

6

Requirement

Requirement

Requirement

Requirement

Requirement6

6

6

4

12 2

1

1 1 1

2

3

4

5

6

Abilitytotilt

Abilitytotranslate

Abilitytorotate

Unitweight

9

3

Compact

Mechanism

3

1

Requirement

Requirement

Request

Request

Request

Handle32hydraulichoses,D=20mm

FulfillEU´slawsandregulationsHighsafety

Lowweight

Compactandrobust

Handleawaterhose,D=70mm

9

1

999

1 3

3 1 1

9 1

Wear

Staticload

Manufacturing

Hydraulicallyremote

3

3

Strenght

Explosionhazard

1

3

3

Technicalityscore

Criteria

CorrelationPositivNegativ

TargetMaximizeValue

StrongAverageWeak

Minimize

Lowcomplexity

Nocorrelation

Relations

Adjustthedrillanglebetween0and-30deg

Performatranslationof

Requirem

ent/Request

drillboomStaticallyhandlealoadof

5tons

11 EnduredustanddirtRequest3

9

9

9

Function Design Safety Other

1 1 1 1 3 1 3 9

3

3

Product

Attributes

--+

-+--

-+--

+

-

+-

+ - + +++

+ ++- +

+ + +- + +

- - -- - -- ++

26

3.3Conceptgeneration

3.3.1Benchmarking

Thebenchmarkingsessionhasfocusedonbrancheswithinmininganddiggingindustrywhereamoreheavilyequipmentcanbefound.Excavatoruseshydrauliccylindersandalsodifferentsortsofhydraulicrotaryunionfortiltandrotation.Thesehavebeentheinspirationforthebrainstormingsessionsdone.

3.3.2Brainstorming

Severalbrainstormingsessionshasbeenexecutedtofillinthemorphologicmatrix.Firstwithownexperienceandtheinformationcollectedfromthebenchmarkingsessions.Thenext session has been with the supervisors both from NECAB and from Karlstad´sUniversity.Thefinalstageofthebrainstorminghasbeenwithclassmateswithagroupofthreestudents.Here,theproblemandwhattobeaccomplishedwaspresentedandthenthetwootherstudentsgot20minutestocomeupwithideasthatsolvedthetwomainfunctions.Allthisinformationwassortedandcategorizedintothemorphologicmatrix,whichcanbeseeninTable5.

SubfunctionsTiltEngine Slewdrive Hydrauliccylinder Hydraulicrotaryactuator Electricrotaryactuator

Cell# 1.1 1.2 1.3 1.4Control Integratedinengine Rotarysensor Geartoothsensor Gyroscopesensor

Cell# 2.1 2.2 2.3 2.4

TranslateEngine Hydrauliccylinder Translationscrew(ball/lead) Rackgear Chainwithsprocket

Cell# 3.1 3.2 3.3 3.4Support Plainbearing Wheels Ballbearing

Cell# 4.1 4.2 4.3 4.4Control Positionsensor Hydrauliccontrolvalve

Cell# 5.1 5.2 5.3 5.4

Subsolutions

Table5:Morphologicmatrixwithsolutionsforthesubfunctions

27

3.4Conceptselection

ThecombinationoftheconceptsfromthemorphologicmatrixaredividedintotwotablesbasedonitsfunctiontoprovidethePahlandBeitzeliminationaneasieroverview,seeTable6.

3.4.1PahlandBeitz

PahlandBeitzeliminationmatrixwasusedintworoundswiththefunctionsseparatedfromeachother.TheresultfromthematrixcanbeseeninFigure14.

Concept1 1.1 2.1

Concept2 1.1 2.2Concept3 1.1 2.3

Concept4 1.1 2.4Concept5 1.2 2.1Concept6 1.2 2.2Concept7 1.2 2.3



Concept12 1.3 2.4Concept13 1.4 2.1Concept14 1.4 2.2Concept15 1.4 2.3Concept16 1.4 2.4

TILTConcept1 3.1 4.1 5.1

Concept2 3.1 4.1 5.2Concept3 3.1 4.2 5.1

Concept4 3.1 4.2 5.2Concept5 3.1 4.3 5.1Concept6 3.1 4.3 5.2Concept7 3.2 4.1 5.1

Concept8 3.2 4.1 5.2Concept9 3.2 4.2 5.1

Concept10 3.2 4.2 5.2Concept11 3.2 4.3 5.1

Concept12 3.2 4.3 5.2Concept13 3.3 4.1 5.1Concept14 3.3 4.1 5.2Concept15 3.3 4.2 5.1Concept16 3.3 4.2 5.2Concept17 3.3 4.3 5.1Concept18 3.3 4.3 5.2Concept19 3.4 4.1 5.1Concept20 3.4 4.1 5.2Concept21 3.4 4.2 5.1Concept22 3.4 4.2 5.2Concept23 3.4 4.3 5.1Concept24 3.4 4.3 5.2

TRANSLATEa) b)

Table6:Combinedconceptsfromthemorphologicmatrixwere,a)isfunction1:Tiltandb)isfunction2:Translate

28

3.4.2Pugh

Those concepts that were decided tomove forward with in each function were nowcombined into newwhole concepts, the following concepts to be evaluated in Pugh´smatrixisconceptnumber(Concept#tilt.Concept#translate):

• 1.1(Concept1.Concept1)• 1.2(Concept1.Concept7)• 1.3(Concept1.Concept13)• 1.4(Concept1.Concept19)• 2.1(Concept6.Concept1)• 2.2(Concept6.Concept7)• 2.3(Concept6.Concept13)• 2.4(Concept6.Concept19)

a) b)

Comment Decision1 + + + + + + +2 + ! + + + + Extracomponents -3 + ! + + + + Extracomponents -4 + + ? + + - Complexgyrosensor -5 + + ? + + + Checkbuilt-insensor +6 + ! + + + + Cylwithaxelsensor? ?7 + + ? + + - Difficulttoachive -8 + + ? + + - Complexgyrosensor -9 + + ? + + ? Rotaryunitwithsensor? ?10 + ! + + + + Rotaryunitwithsensor? ?11 + + ? + + - Difficulttoachive -12 + + ? + + - Complexgyrosensor -13 + ! ? - ! - Can´tcombine -14 + ! + - ! - Complex.Gearbox? -15 + ! + - ! - Complex.Gearbox? -16 + ! ? - ! - Complexgyrosensor -

(-)Notpassed(?)Gathermoreinformation(!)Checkspecification

(?)Moreinforequired(!)Checkspecification

Decision

Enoughinfo

(-)No

(+)Passes

Concept#

Solvesmainfunction


Realizable

Safeandergonom

ic


Function1:Tilt Eliminationcriteria(+)Yes

Comment Decision1 + + + + + + Telescope +

2 + + ? + + - Waitfornow ?

3 + ! ? + + - Notthatcompact ?


5 + ! ? + + - Lowlifetime -

6 + ! ? + + - Lowlifetime -

7 + + + + + + Needstobeprotected +

8 + + - + + - Notrealizable -


10 + ! - + + - Notrealizable -

11 + ! - + + - Lowlifetime -

12 + ! - + + - Notrealizable,lowlifetime -

13 + + + + + + +




17 + ! ? + + - Lowlifetime -

18 + ! - + + - Notrealizable,lowlifetime -

19 + + + + + ? Newdrillboom? +


21 + ! + + + + Waitfornow -

22 + ! - + + + Notrealizable -

23 + ! - + + + Lowlifetime -


(+)Passes

(-)Notpassed

(?)Gathermoreinformation

(!)Checkspecification

Safeandergonom

ic


Enoughinfo

(-)No

(?)Moreinforequired

(!)Checkspecification

Decision

Concept#

Solvesmainfunction


Realizable

Function2:Translate Eliminationcriteria(+)Yes

Figure14:PahlandBeitzeliminationmatrixfor,a)Function1:Tiltandb)Function2:Translate

29

Concept1.1wassetasthereferenceconceptsincetheconceptisfirstinorder,thismakesiteasiertofollow.FromPugh´smatrixinFigure15,theconceptstobefurtherdevelopedareconcept1.1,2.1and2.3.

Weight 1.1[ref] 1.2 1.3 1.4 2.1 2.2 2.3 2.4

Compact 1 0 0 - 0 0 0 -

Enduredust&dirt 3 - - - + 0 0 0

Lowcomplexity 2 - 0 - + 0 + -

Lowcost 1 - - - + 0 0 0

Highreliability 3 - 0 - + - 0 -

Stabilizeposition 2 - - - - - - -

Easytodesign 2 0 0 0 + 0 + 0

Easytoassemble 1 - 0 - + - + -

0 0 0 12 0 5 0

3 9 2 1 9 8 6

12 6 13 2 6 2 9

0 -12 -6 -13 10 -6 3 -9

3 6 4 7 1 4 2 5Yes No No No Yes No Yes

Netvalue

Rank

Furtherdevelopment

CriterionsConcept#

Sum+

Sum0

Sum-

Figure15:Pugh´smatrix

30

3.4.3Explanationofconcepts

Togetabiggerperspectiveonhowtheconceptwouldlooklike,fastandnotsodetailed3D models of the individual function were created. Pugh´s matrix resulted in threeconceptswithfourdifferentingoingsubsolutions.Thefollowingfiguresshowsthesubsolution in respectively function with descriptions on how it works and with itsadvantagesanddisadvantages.

3.4.3.aFunction1:Tilt

In Figure 16, the solution for tilt is a slew drive that rotates the lower part of theattachment.Thesolutioniscompactandcanhandlethestaticpositionofthedrillwelldue to the self-lockingmechanism in the encapsulatedworm gear. The slew drive isresistanttodustanddirtduetoitsincapsulateddesignwithlittleneedformaintenance.Toplacethedrillinlinewiththecenterofgravitytoavoidhavingabendingmomentinthe base, the design becomesunnecessarily complex. The solution also involvesmorepartsandlotsofscrewsrelativetothehydrauliccylinder.Tocontrolthetiltangle,abuilt-inhallsensoriseasytomountinoneoftheendsintheslewdrive.

Figure16:Slewdriveassolutionfortilt

31

Cylinderfortiltandtranslationisasimpleandreliablesolutionandiswellimplementedintheminingindustryalready.ThesolutioninFigure17isahydrauliccylinderwhichisconnectedbetweentheupperpartandthelowerpartoftheattachment.Thesolutionissturdyandeasytocontrol,thecylinderwillbeequippedwithbuiltinsensortocontrolthe angularpositionof the attachment.The cylinderneeds external scraper rings andmaybeacovertomakesurethedustanddirtisrejectedasbestaspossible.Thedrillisplacedinlinewiththecenterofgravitywhichcreatesafavorablestressdistributionandleadstonocompromisesindesign.

Figure17:Hydrauliccylinderassolutionfortilt

32

3.4.3.bFunction2:Translate

InFigure18,thesolutionwithacylinderfortranslationisareliablesolutionbutitisnotcompactandcannotutilizethewholedrillboomasdistancetotranslate.Withthissaid,atelescopiccylindermightbenecessarytouse.Thecylinderneeds,asdescribedbefore,scraperringsandmaybeacoverfordustanddirt.Thecylinderisfavorablebecauseofthesymmetrical load, created due to the force is pushing/pulling in the center of theattachment.

Figure18:Cylinderassolutionfortranslation

Figure19:Rackandpinionassolutionfortranslation

33

Onesolutiontothetranslationistoletitbepoweredbyahydraulicmotorandasetofrackandpinion, seeFigure19.This solution is compact, canutilizeall the translationlengthandisstable.Thedisadvantagesarethepotentialareafordustanddirttosneakinbetweentheteeth’sandmayleadtofailure.Thisincreasesthemaintenanceandaneedforaprotectioncovermightbenecessary.Itwillalsocreatehighstressesandbendingmomentsontheteeth.Themotorneedstobeequippedwithintegratedsensorstobeabletolocatethestartingpositionofthedrilloruseanexternalsensor.

TheremainingconceptsafterPugh´seliminationmatrixare:

• Concept1.1:Slewdrivefortiltandahydrauliccylinderfortranslation• Concept2.1:Ahydrauliccylinderfortiltandtranslation

• Concept2.3:Ahydrauliccylinderfortiltandarackandpinionfortranslation

3.4.4Kesselring

Afterthe3DconceptCADdrawings,theinsighttothedifferentconceptbecameclearer.TheKesselring’scriteriamatrix isseen inFigure20andshowstheconceptsvalued inpoints.Concept2.1wastheconcept thatgot themostpointsbutafterdiscussionwithNECABtheconceptthatwasdecidedtomovefurtherwith,wasconcept2.3.

Figure20:Kesselring´scriteriamatrix

Projectdescription

DrillBoomAttachment

Criteria ExplanationPoints Weight Points WxP Comment Points WxP Comment Points WxP Comment1:Lowcompactness5:Highcompactness1:Fulfillsbad5:Fullfillswell1:Highcomplexity5:Lowcomplexity1:Highcost Gearbox5:Lowcost1:Lowreliability5:Highreliability1:Fulfillsbad5:Fullfillswell1:Fulfillsbad SeeCAD SeeCAD5:Fullfillswell1:Fulfillsbad Lotsofscrews!! Engine,gearbox5:Fullfillswell1:Alotofmaintenance Scraperringfor Scraperringfor5:Littlemaintenance dustanddirtetc dustanddirtetc1:Fulfillsbad5:Fullfillswell

119 135 131Decision:Concept2.3

Maintenance 4 4 16 3 12

4 20

4 16

Handlehooses 5 3 15 4 20

Easytoassemble 3 2 6 5 15 3 9

Easytodesign 3 3 9 4 12 4 12

Stabilizestaticposition 5 4 20 3 15 4 20

Reliability 4 4 16 4 16 4 16

Cost 2 3 6 4 8 2 4

3 6

3 12

Complexity 3 3 9 5 15 4 12

Approvedandsignedby:

Concept1.1 Concept2.1 Concept2.3

5 10

Enduredustanddirt 4 4 16 4 16

Compactness 2 3 6

Slewdrive fortiltCylinderfortranslationSlidebushingsforsupport

CylinderfortiltCylinderfortranslationSlidebushingsforsupport

Cylinder fortiltRackandpinionfortranslationSlidebushingsforsupport

ExplanationWeight

1:Not important5:Veryimportant

34

3.4.5FMEA

InFigure21,theFMEAresultoftheproductisshowed.Themostcriticalpotentialfailureisstressfailuresinthecomponents.Tosolvethis,structuralverificationswillbeofbiggerimportancewhendimensioningthecomponents.ThenewfailureanalysisshowsthattheSODnumberwasdrasticallylowerafterimplementedtherecommendedaction.Thenextimportantfailuretolookoutforisdustanddirtthatmayenterinbetweencomponents.Tosolvethis,scrapersmountedtothecylinderandtotheattachmentissuggestedasasolution.Regularlycleaningofthesurfacesthatisexposedisalsoarecommendedaction,thisactionisdedicatedtotherackandpinionthatishardtoincapsulate.

FMEA Process X

dateSledge Thesledgewearto- Increased- Dust&dirt

drillboom wearSledge Thesledgetwistsand- Drillboom- Unevenload-

pinches pinches caseCylinder Possibleleakageinseal Leakage Dust&dirt

Rack&pinion Yieldfailureinteeth Motionloss Stresses

Sledge Failureinmaterial Dropsthedrill Stresses

Topattachment Failureinweldsorin- Dropsthedrill Stressesmaterial

Hooses Thehosesdoesnotfit- Brokenhose Badlinefor-andmaybuckle hoses

Rack&pinion Stackofdirtinteeth Wearin- Useinamineteeth

Function/Construction

Project/Object Issuer DateBachelorthesis NiklasBerntsson 2021-04-03

SID Part/Process FunctionFailureCharacteristics Failureanalysis

Recommendedaction

Designation Edition PageDrillBoomAttachment 1 1

4 4 4 64bushings

O D SOD

1 4 8 4 128 Coversorscrapersfor- 2021-05-03

Done-Newfailureanalysis

Potentialfailure Consequence Cause S O D SOD

2021-04-25 5 2 5 50enginesoneachside

2 5 7 5 175 Useoftwohydraulic-

2021-04-25 3 3 3 273 3 6 3 54 ScrapersincylinderTilt

2021-05-03 8 2 7 1124 8 4 7 224 DimensiontherackLinearmotion

2021-05-03 9 2 7 1265 9 4 7 252 DimensionthesledgeSupportdrill

2021-05-03 9 2 7 126onweldsandpart

6 9 4 7 252 Useofconstructivdesign-Supportdrill

2021-04-12 7 1 3 21priortizethehoses

7 7 3 3 63 Makeroomand-Handlehoses

2021-05-03 5 4 1 20runcleantheteeth´s

8 5 8 2 80 Opendesignandforevery-Linearmotion

Translate

Translate

Figure21:ResultoftheFMEAanalysisoftheproduct

35

3.5Designandstructuralverification

Figure22 is showing the thoroughmechanical components for the finaldesignand inAppendixC,themodeltreeoverviewispresented.

Figure22:Componentoverviewoffinalconcept

A

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B

C

D

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F

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A

B

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Drawing no.

General tolerance acc. to ISO 2768-class General surface roughness Ra µm

Issue SheetKARLSTADS UNIVERSITET

MAIN_EN 2021-05-04 1:4Designed by Model name Date Scale

Itemref Quantity Title/Name. designation. material. dimension etcArticle No./Reference

1 1 BASE_PLATFORM

2 1 BAS_TRANSLATE_EN

3 1 LOWER_ATTACHMENT

4 1 UPPER_ATTACHMENT

TETSTST

1 (1)

Date Signed Description of revision Zone Issue

Cylinder mount

Bushing holder x4

Planetary gearbox x2

Hydraulic motor x2

Rack & Pinion set x2

Tilt cylinder

36

The following calculations and verifications in the design- and structural verificationchapterareusingtheacronymsfromTable7.

Table7:Acronymsforcalculationchapter

Description Acronym Unit

Safetyfactor n -Leverfromeffectiveforce l mmForceneededfromcylinder F c N

Accelerationforce F a NAccelerationofdrillboom a m/s2

Pitchdiameter d 0 mmModulofpinion Mn -Numberofteeth´s z -Overallefficiency η -

Torqueneededfromgearbox T NmDiameterinshaft d mm

Areaofcrosssection A mm2

Bendingmoment M NmmShearstress ! MpaPlainstress σ Mpa

Bendingstress σ b MpaBendingresistance W b mm3

Forcebygravity F g NWidthofholder b mmHeightofholder h mm

37

3.5.1Design

Ahydrauliccylinderisusedtoachievethetiltfunctioninconcept2.3.Themomentneededcomesfromequation1intheprestudy.Todimensioningthecylinder,tworequirementsareneeded.

• Forceneededfromcylindertopullthedrillboombackto0°• Strokeincylindertotiltthedrill30°

ThemomentMtwas17600Nmandfromequation4theneededforceiscalculated.

Themaxforceneededfromthecylinderwhenliftingthedrillwas86,7kN.Thecylinderneedstohandlethatloadatpullingbecauseitrequiresmoreforcetodefygravitythenworkingwithit.

Tochoosethestrokeofthecylinderneededtotiltthedrill30°,a3DsimulationmodelinCREOwascreated.Thestrokewastheneasytocalculateanddetermine,seeFigure23.

Withthesimulationdonethestrokechosenoncylinderis135mm.

CylinderwasselectedfromArcosHydraulicsJKV-2300Series[12]withapistondiameterof80mmandapistonroddiameteron40mm.Partnr:2300F-080-0135-040-HVP-045

𝑙 = 264mm 𝑛 = 1,3

𝐹( = 𝑛 ∙𝑀! ∙ 1000

𝑙 (4)

a) b)

Figure23:StrokesimulationinCREO.a)at0°,b)at30°

38

Inconcept2.3,asetwithrackandpinionwithahydraulicmotorandaplanetarygearboxisused.Todimensionthese,threecriterionsareneeded:

• Forceactingonrack• Moduleandnumberofteeth´satthepinion• Torqueneededtodrivethepinion

Fromequation2intheprestudy,thefeed-forceexertedontherackwascalculatedto34,5kN.Thisfeed-forceisthefactortodimensiontherackandpinionby.Todimensiontherackandpinion,atablefromApexDynamicsisusediteratively[13].Thepinionthatwasselectedhashelical teethand iswelded toaplateand thenmounted to theplanetarygearboxwithscrewsformaximumstrength.Theselectedpinionhasamoduleof4and19numberofteeth´s.Thepinioncombiningwithamatchingrackcanhandlefeedforceson36,2kNandamaxtorqueon1460Nm.RackandpinionaredeliveredbyOEM-motors.

Thetorqueneededwascalculatedinequation5andistheminimumtorqueoutfromthegearboxtodrivethepinionandcreatethetranslation.

𝑎 = 0,1ms! 𝑀𝑛 = 4 𝑧 = 19 𝑑$ = 𝑚𝑜 ∙ 𝑧 = 72mm 𝜂 = 0,95 𝑛 = 1,3

The torque is distributed over two gearboxes on each side of the drill boom, so todimensionthegearandmotor,thetorquewasdividedbytwo.Thetorqueneededfromthegearboxwasthen910,3Nm.ThegearboxselectedwasaplanetarygearboxfromApexDynamics AD series: Part nr: AD2001-P0403600601 [14]. The motor to drive thesegearboxes was selected in consultation with LKAB and NECAB to be a Danfoss OMRhydraulicmotor.

𝑇 = 𝑛 ∙(𝐹 + 𝐹#) ∙ 𝑑)2000 ∙ 𝜂 = 1820,6Nm (5)

39

3.5.2Structuralverification

Thefactorsinmaterialselectionforthestructureare,goodweldability,lowweightandhighstrength.Thematerialtouseissteelandthefollowingsteelalloysarespecifiedasgood candidates; S235, S275 and S355. All the candidates are low alloy generalconstruction steelswith goodweldability and high strength [15]. The S355 steelwaschosentobeusedinthisproducttominimizeweightandoptimizethestrength.

The factors for the slide bushings are, low friction, high strength and high surfacetoughnesswhichwillminimizethewearinthematerial.Table8showsthemostcommonusedmaterialforslidebushings.ThePTFEplasticwaschosenasslidebushingmaterialbecauseofitslowfrictionanditsgoodavailabilityinthemarket[16].

Table8:Tableovermaterialpropertiesofthemostcommonplastics

Material Yieldstrenght Friction Wear[MPa] [∝/km]

PP-H 30 0.30 11PE-HD500 28 0.29 1

PC 60 0.55 22POM-C 65 0.32 8.9PA6 85 0.40 0.23PET 80 0.25 0.35PTFE 25 0.01 21PEEK 95 0.35 -ABS 50 0.50 8.4

40

3.5.2.aCylindermount

ThecylindermountwasdesignedsothestresseswouldbedistributedasbestaspossibleandreducethestressconcentrationsaccordingtoHelmeretal.[10].ThecalculationlaystodeterminetheshearstressesinthecylindershaftwithformulasfromBjörk[17].

𝐹 = 67000N 𝑑 = 45mm 𝑛 = 1,5

Maximumshearstrengthincylindermountwas110MPaandtoverifythesenumbersaFEManalysisisdone.TheFEManalysisisshowninFigure24withstresseson91MPaattheinsideofthehole.

𝜏 = 𝑛 ∙𝐹𝐴

(6)

𝜎 = 𝜏 ∙ √3 (7)

Figure24:FEManalysisoncylindermount

41

3.5.2.bBushingholder

Thebushingholderistheholderfortheslidebushingsthatcontributestolowerfrictionbetweendrillboomandtheattachment.Thesebushingholders,holdalltheweightofthedrill, so a material strength analysis on these must be done. The holders can beapproximatedtoabeamwhichisfixedinoneendwithcalculationaccordingtoBjörk[17]

𝐹 = 13500N 𝐿 = 35mm 𝑏 = 150mm ℎ = 15mm 𝑛 = 1,5

Theplainstresscalculatedfromequation12intheholder,originatesfromthebendingstress,equation8andtheshearstress,equation10whichoccursfromthetotalmassload.Theplainstressachieves127MPa.AFEManalysisconfirmsthat,whichcanbeseeninFigure25.TheFEManalysisshowsstressesat75MPawithoutthesafetyfactor.

𝜎* = 𝑛 ∙𝑀𝑊* (8)

𝑊* =𝑏 ∙ ℎ+

12 (9)

𝜏 = 𝑛 ∙𝐹𝐴

(10)

𝐴 = 𝑏 ∙ ℎ (11)

𝜎 = \𝜎*+ + 3 ∙ 𝜏+ (12)

Figure25:FEManalysisonbushingholder

42

3.5.2.cFEMonbasestructure

Theweight of the base structure is to beminimized in those areas where the stressconcentrationsarelowest.TheFEManalysisinFigure26showsstressesat24MPawhentheforceisvertical.InFigure27theresultis30MPawhentheloadistilted30°.Millingcutsaremadeintheareaswithloweststressconcentration.

Figure26:Femanalysisonbasestructurewhentheforceisvertical

Figure27:FEManalysisonbasestructurewhentilted30°

43

InFigure28, theFEMresult isshownto theplate that isconnectedto theupperslewdrive.Forcesbothwhen thecylinder ispullingandalsoby thegravity is represented.Stressesoccursintheradiusoftheweightoptimizationandisat38MPa.

Figure28:FEManalysisonupperplate

44

Figure29showsthefinaldesignofthedrillboomattachmentplacedinitsfictiveminewheretheattachmentshalloperatein.

A

1 2 3 4 5 6 7 8 9 10 11 12

B

C

D

E

F

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A

B

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E

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1 2 3 4 5 6 7 8 9 10 11 12

Drawing no.

General tolerance acc. to ISO 2768-class General surface roughness Ra µm

Issue SheetKARLSTADS UNIVERSITET

KONCEPT_6_EXJOBB 2021-05-11 77:5000Designed by Model name Date Scale

Itemref Quantity Title/Name. designation. material. dimension etcArticle No./Reference

1 1 KONCEPT_6_EXJOBB_1

2 1 MECHANISM

DRW0001

1 (1)

Date Signed Description of revision Zone Issue

Figure29:Drillboomattachmentplacedinthefictivemine

45

4Discussion

TheDoubleDiamondtheorythatwasusedinthisthesisleadtoasystematicandaccurateproductdevelopmentmethod.Itwasaguideforalltheinvolvedprocessessothatnostagewasmissed.Themethodandtheorychapterweremergedtogether,thisgaveaclearerandamore structural approach to the report. If theywouldhavebeen separated, themethod chapter would just have been basically an iteration from the theory chaptersayingthatthesessioninthetheoryhadbeenperformed.

Thebrainstormingsessionsthatwereusedinseveralstagesworkedwellbutcouldhaveworkedbetter.ThereasonforthatisCovid-19.Tobecreativeandworkoutsidetheboxis harder in an apartmentwhere the inspiration is lower. TheCovid-19 regulated thebrainstormingsessionsintobeingonlinesessions,thisisnotoptimal,butitworks.Thebenchmarkingsessionsweredoneeitheronlineatdifferentsitesontheinternetoroutatpublic. The opportunity to see different solutions on excavators, drilling rigs etc.wastakeneverytimewhenanexcavatororaheavy-dutymachinewasseeninpublic.

In the development process, theQFDhelped to highlight the partswhich the productattributeshadethemostoutcomesover.This ledtoa fasterandeasierdesignprocesswhentheproductwouldbe3Dmodeledinalaterstage.TheproductFMEAthatwasdoneafterthefinalconceptselectionsessionalsoacceleratedthe3Ddesign.

UlrichandEppinger´sstrategicalmethodforselectingaconceptwasreallyasystematicapproach.ThePahlandBeitzeliminationmatrixwasdone in twostages,one foreachfunction.Thiswasdonebecauseofamoremanageablehandlingoftheconceptselectionphase.Ifbothfunctionswouldhavebeenintoonematrix,thetotalnumberofconceptswouldhavebeendrasticallyhigher.

InbothPugh´sandKesselring´scriteriamatrix,concept2.1scoredhigherthanconcept2.3,butintheendwhenselectingthefinalconcept,concept2.3won.Thisisimportanttoknowandrealizethatthescoringfromdifferentmatricesmightnotbeasaccurateandvalidinreality.Thereasonwhyconcept2.3wasselectedasfinaldesignwasforthereasonthat the components were placed in the middle of the drill shaft. This gives a morefavorabledesignwhenrotatingandmaneuveringthedrill.Thisdesignisnotasexposedtobehitbyanexternalobjectcomparedtoconcept2.1whereacylinderisplacedatthefarendofthedrillboom.

Fromaninitialstage,theconceptwastohaveasinglehydraulicmotortodrivethepinion.Aftersomebasiccalculationwhenthemasswascountedfromthe3Dmodel,thetorqueneededfromthemotorwasconsiderablylowerthanrequired.Theconceptthenchangedtoincludesomesortofgearboxandalsohaveasetofthematbothsides.Afterresearchand contact with different companies which are supplier for different gearboxes, aplanetarygearboxwasselectedtouse.ThediscussioncontinuedwithAPEXdynamicsandtheir AD series was then decided to use with a matching rack and pinion. To add a

46

planetarygearboxhasdisadvantagesincompactness,costandweight.Thegearboxgetsinthewayforthepivotpinsoformaintenanceontheattachment,oneofthegearboxesneeds to be disassembled. A total of four screws and loosen themotor axle from thegearboxwillneedtobedonebeforeremovingthepivotpin.

Thechoiceofrackandpinionsetwasmostlychosentominimizethetorqueneededfromthegearbox,alowpitchdiametergivesthelowesttorqueneededoutfromtheplanetarygearbox.Whenincreasingthepitchdiameter,theteeth´sstrengthbecomeshigherbutsodoes the needed torque from the gearbox, this was a dilemma that needed to beaddressed.

Thebasestructureismadeof25mmS355steel,whichisanoversizinginstresseswithsafetyfactorsover4.Thisisdonebecauseoftheweldeddesign.Oversizingthematerialimproves the initial stageofa fatiguecrack inaweldeddesign.This leads toahigherfatigue strength. It is also favorable to allow the same parts that needs to beweldedtogether tobe in thesamematerial thickness [10].The thicknessof theplates is thenchosenregardingtotheminimumsheetthicknessneededinthepartswherethestressesishighest.Theotherpartswillthenbeinthesamethickness.

Thesheetthicknessisalsosetto25mmbecauseoftherigidityandthelookofastablestructure.Thisgivesanimpressionandafeelthattheproductissafe,thisiscategorizedasapsychologicalfunctiontheperceivedcharacteristicsaccordingtoJohannessonetal.[5].

Afewmillingcutsweredonetoreducetheweightinthosepartswhereitcouldbedone.SeveralFEManalyseswasusedtolocatetheseareaswherethestressdistributionwaslowest.TheFEManalyseswasdoneiterativelywithandwithoutthemillingcutstoseewhat the stressdistribution looked like and later onmake thesemilling cuts in thoseareas.Thisprovideda learning lessonandagreater insight intohowthestresseswasdistributedinthematerial.

47

5Conclusion

ThisbachelorthesishaditsmaingoaltogenerateaconceptforLKABtotheirnewminingsystem.Theaimistodevelopatwo-partedmechanicalattachmentforadrillrigusingmodernproductdevelopmenttechniques.

Theresultisanattachmentpoweredwithahydrauliccylinderthatcontrolsthetiltangleof the drilling hole. The hydraulic cylinder is an implemented solution already in theindustryanditturnedoutthatitisthebestsolutioninthisfunctionaswell.

Theresulttomaneuverthetranslationofthedrillboomisamechanicalsystemcontaininga hydraulicmotor, a planetary gearbox and a set of rack andpinion. This system is acompactandasturdywayoffusing thewholedrillboomas translationdistance.Thissetupisusedtwiceinthisproductoneachsideofthedrillboom.

5.1Futurework

Whendiscussionwiththesupplierforthegearboxandtherackandpiniontheysuggestedtousea lubricationsystemfortherackandpiniontoenhancethe lifetime.This isnotsomethingthereportfocusedon,butitmightbeausefulideatoincludethislubricationsystemintheconcept.

Thesensors integrated in thehydraulic cylinderand in thehydraulicmotor isnotyetdetermined.Itwillalsoneedtodevelopanddesigntheclampsthatwillsupportthehosesandtheelectricharnesses.Thishasnotbeendone,becauseofitsyetnotdetermineddrillriganddrillmagazine.

48

References

[1] JanssonT,LjungL.Individer,GrupperochLedarskapiProjekt.2.uppl.Lund:Studentlitteratur;2017.

[2] DesignCouncil.Whatistheframeworkforinnovation?DesignCouncil´sevolvedDoubleDiamond[internet].London:DesignCouncil;2015[cited2021-02-17].Availablefrom:https://www.designcouncil.org.uk/news-opinion/what-framework-innovation-design-councils-evolved-double-diamond.

[3] Digi-ark.DoubleDiamondDesignProcess[digitalpicture].2020[cited2020-02-17].Availablefrom:https://commons.wikimedia.org/wiki/File:Double_diamond.png.CC01.0UniversalPublicDomainDedication.

[4] ErikssonM,LilliesköldJ.Handbokförmindreprojekt.1.uppl.Stockholm:Liber;2009.

[5] JohannessonH,PerssonJ,PetterssonD.Produktutveckling:Effektivametoderförkonstruktionochdesign.2.uppl.Stockholm:Liber;2012.

[6] Berg-ochgruvarbete(AFS2010:1).Stockholm:Arbetsmiljöverket.

[7] ATEXdirective(2014/34/EU).EuropeanUnion:TheEuropeanParliamentandtheCounciloftheEuropeanUnion.

[8] Machinerydirective(2006/42/EC).EuropeanUnion:TheEuropeanParliamentandtheCounciloftheEuropeanUnion.

[9] SundströmJ,AnderssonP-E,BjärnemoR.KonstruktivutformningDel1:Syntes.Lund:Lundstekniskahögskola;2000.

[10] HelmerF,BjärnemoR.KonstruktivutformningDel2:AnalysochOptimering.Lund:Lundstekniskahögskola;2001.

[11] BergmanB,KlefsjöB.Kvalitetfrånbehovtillanvändning.5.uppl.Lund:Studentlitteratur;2012.

[12] ARCOSHYDRAULIKAB.JKV-2300SERIESCONTENTS[internet].[cited2020-04-30].Availablefrom:https://adobeindd.com/view/publications/8040273a-17cf-42cd-a640-055ec682597c/1/publication-web-resources/pdf/ArcosHydraulik-JKV-2300.pdf

49

[13] APEXDYNAMICS,INC.HighPrecisionRackandPinion[internet].[cited2020-04-30].Availablefrom:https://www.apexdyna.se/ui/product-resources/oem/apex-kuggstänger-och-drev-_-178310.pdf?att=False&hash=5F4FA1E8DC78A612084C03B0E9C70BB5

[14] APEXDYNAMICS,INC.HIGHPRECISION,HIGHSPEED,PLANETARYGEARBOX,AD/ADR/ADSSeries[internet].[cited2020-04-30].Availablefromhttps://www.apexdyna.se/ui/product-resources/oem/-_-131873.pdf?att=False&hash=62779AA9406A9A92D583F6C7802783FB

[15] BEGroupSverigeAB.BYGGSTÅLSHANDBOKEN[internet].Malmö;2016[cited2020-04-22].Availablefrom:https://www.begroup.se/fileadmin/user_upload/images_and_files/Sweden/Documents_and_files_BE_Group_Sweden/Broschures_and_product_info/Broschyrer/BE_Byggstalshandboken_okt_2016.pdf

[16] NordicPlasticsGroup.Plaster[internet].Trelleborg;d.u.[cited2020-04-22].Availablefrom:https://www.npgroup.se/plaster/

[17] BjörkK.Formlerochtabellerförmekaniskkonstruktion.8.Edition.Märsta:KarlBjörksförlag;2017.

50

Appendix

AppendixA,WBS

Process

1Planning

1.1Projectplan

1.1.1Background

1.1.2Aims&Limitations

1.1.3Organization

1.1.4Projectmodel

1.1.5FMEAprocess

1.1.6Appendix

1.1.6.1WBS

1.1.6.2GANTT


1.2.1Pilotstudy

1.2.2Requirement &

demands

1.2.3Arranging &weightning

1.2.4QFD

1.2.5Send drafttoNECAB

1.2.6Completebased onresponce

1.2.7Gate

2Concept

2.1Conceptgeneration

2.1.1Benchmarking

2.1.2Ideageneration

2.1.3Brainstorming

2.1.4Morfologicmatrix

2.1.5Polygontrain

2.2Conceptselection

2.2.1Ulrich&Eppinger

2.2.2Pahl&Beitz

2.2.3Pugh

2.2.4Kesselring

2.2.5Gate

2.2.6FMEAProduct

3Design

3.1Modeltree

3.2Calculations

3.3CAD

3.4FEM

4Closure

4.1Finalpresentation

4.2Opposition

4.3Final report

51

AppendixB,Gantt

Examensarbete18 jan 2021 - 7 jun 2021Huvudadministratör: Niklas Berntsson

Utskriftsdatum: 12 apr 2021 - Examensarbete 1/1

Namn v5 - 1 feb v9 - 1 mar v13 - 1 apr v17 - 1 maj v22 - 1 jun

1) Kursstart

2) Planning Phase

3) WBS Process

4) Gantt

5) Project plan

6) Meeting NECAB

7) FMEA Process

8) WBS Product

9) Prep Presentation

10) Submission Projectplan

11) Presentation Projectplan

12) Product specification

13) Requirementspecification

14) QFD

15) Gate productspecification16) Report writing t.o.mmethod

17) Concept Phase

18) Concept generation

19) Benchmarking

20) Idea generation

21) Teamwork

22) Brainstorming

23) Morfologic matrix

24) Concept selection

25) Ulrich & Eppinger

26) Submission Methodchapter

27) Prep presentation

28) Pugh elimination

29) Kesselring

30) Half-time presentation

31) Gate concept

32) FMEA Product

33) Design Phase

34) Material selection

35) Calculations

36) CAD

37) FEM

38) Closure Phase

39) Deadline report foropposition

40) Final Presentation

41) Submission writtenopposition

42) Submission Final Report

18 jan

18 jan - 17 feb

18 jan - 18 jan

18 jan - 19 jan

19 jan - 29 jan

19 jan

19 jan - 20 jan

22 jan - 22 jan

25 jan - 26 jan

29 jan

2 feb

1 feb - 9 feb

1 feb - 3 feb

8 feb - 9 feb

15 feb

15 feb - 17 feb

22 feb - 6 apr

22 feb - 16 mar

22 feb - 23 feb

24 feb - 3 mar

3 mar - 3 mar

8 mar - 9 mar

8 mar - 16 mar

17 mar - 6 apr

17 mar - 22 mar

19 mar

22 mar - 23 mar

23 mar - 29 mar

29 mar - 30 mar

30 mar

31 mar

5 apr - 6 apr

12 apr - 5 maj

12 apr - 12 apr

12 apr - 19 apr

19 apr - 2 maj

3 maj - 5 maj

10 maj - 7 jun

17 maj

25 maj

27 maj

7 jun

52

AppendixC,Modeltree

BASE_PLATFORM

MainMainasm

Subasm

Custompart

Boughtpart

LOWER_ATTACHMENT

PLATFORM

SLEW_HP_WD_H0645

UPPER_ATTACHMENT

SLEW_MOUNT

CYL_BRACKET(X2)

CYL_ATT(X2)

SLEDGE_BRACKET(X2)

UPPER_CYL_ADAPTER

CYL_SHAFT

SHAFT_LOCK

CYLINDER_2300

M16X30

BASE_DRILL

SLEDGE

SPRING_PIN(X2)

HOLDER_BRACKET

SLEDGE_SHAFT

SHAFT_LOCK

CYL_ATT

CYL_ATT_SHAFT

SHAFT_LOCK

M16X30

SLIDE

BUSHING_PLATE(X4)

BUSHING(X4)

M8X22(X12)

M6_FLANGE_NUT(X12)

M6X22(X12)

DRIVE_SYS

SCRAPER(X4)

DRILLBOOM

DRILL

ENGINE_MOUNT(X2)

DANFOSS_OMR(X2)

SHAFT_ADAPTER(X2)

PINION(X2)

RACK(X2)

RACK_HOLDER(X2)

SCRAPER(X4)

PROFILE(X4)

M8X60(X32)

M12X30(X12)

M8X40(X24)

PLANET(X2)