Design For Assembly

11/24/2017
Contents
 Assembly Types and Operations
 General Guidelines for Assembly
 Designing Assembly Interfaces
 Designing Interface Elements
Design of Mechanical Systems  Guidelines for Application and Selection
Unit VI
Types of Assembly Types of Assembly

Move,
 The cost and quality of an assembly depend on the type and number of
Orient, Preposition
operations and on their execution. Manual
 The type and number, in their turn, depend on the layout design of the
Power Tool for fastening
product, on the form design of the components and on the type of
production (one-off or batch production).
Part Feeders (Vibratory
Layout design of bowl)
product Assembly Automatic
Automatic Work head

Type and
Form design of
Number of
product
Assembly Cost operations
Robot under computer
and Quality Robotic
Control
Execution of Type of
Operations production
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Assembly Operations
Assembly
Operations  The cost of assembly is determined by the number
of parts in the assembly and the ease with which
Storing Handling Positioning Joining Adjusting Securing Inspection
the parts can be handled, inserted, and fastened.
Inserting  Design can have a strong influence in both areas.
Pressing  Reduction in the number of parts can be achieved
Together
by :
Fusing,
Casting,  elimination of parts (e.g., replacing screws and washers
with snap or press fits), and
Bending
 by combining several parts into a single component
Welding,
Gluing
General Guidelines for Assembly General Guidelines for Assembly

 It seems useful to start considering assembly even  Use of guidelines lead to a reduction in expenditure
while working on the working structure and the because the assembly process is improved and to
layout. increase in product quality because assembly is clearer
 An easy-to-assemble layout can be achieved if the and easier to control.
assembly operations are:  A layout that has been selected for these reasons could
 structured also lead a reduction in the number of components or
 reduced at least the standardization of components
 standardized
 simplified.
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General Guidelines for Assembly: General Guidelines for Assembly:

Arrange Assembly Operations Arrange Assembly Operations
St-Storing, Ha-Handling, Po-Positioning, Jo-Joining, Ad-Adjusting, Se-Secure, In-Inspection, St-Storing, Ha-Handling, Po-Positioning, Jo-Joining, Ad-Adjusting, Se-Secure, In-Inspection,
MA-Manual Assembly, AA-Automated Assembly MA-Manual Assembly, AA-Automated Assembly

Reduce Assembly Operations Reduce Assembly Operations
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Standardize Assembly Operations Simplify Assembly Operations
Designing Assembly Interfaces:

Designing Assembly Interfaces Reduce Interfaces
 Another important aspect of improving assembly is the
design of interfaces that are influenced by the layout.
 Improvements to the interfaces are achieved if they are:
 reduced
 standardized
 simplified.
 These actions reduce the number of connecting elements
and assembly operations, and minimize the quality
requirements of the interfacing elements
St-Storing, Ha-Handling, Po-Positioning, Jo-Joining, Ad-Adjusting, Se-Secure, In-Inspection,

MA-Manual Assembly, AA-Automated Assembly
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Designing Assembly Interfaces: Designing Assembly Interfaces:

Reduce Interfaces… Standardize Interfaces…

Simplify Interfaces Simplify Interfaces…

MA-Manual Assembly, AA-Automated Assembly St-Storing, Ha-Handling, Po-Positioning, Jo-Joining, Ad-Adjusting, Se-Secure, In-Inspection,
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Simplify Interfaces… Simplify Interfaces…

Simplify Interfaces… Simplify Interfaces…
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Simplify Interfaces… Designing Assembly Interfaces
 Closely linked to the design of interfaces is the design of the
interfacing elements.
 To improve automatic storage and handling, including the
identification, ordering, picking-up and moving of the
interfacing elements, these operations should be:
 enabled
 simplified.
 This is particularly important for the application of automatic
assembly machines (AA).
 The essential guidelines can be derived from the basic guidelines
of simplicity(simplify, standardize, reduce) and clarity(avoiding
over constraining and under constraining)

Enable and Simplify Automatic Storage and Handling Enable and Simplify Automatic Storage and Handling
St-Storing, Ha-Handling, MA-Manual Assembly, AA-Automated Assembly

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Guidelines for Application and

Enable and Simplify Automatic Storage and Handling Selection
Design for assembly should, involve the following five steps at appropriate
stages of the design process.
 Step 1: Draw-up demands and wishes for the requirements list that
determine or influence assembly.
 individually designed product or variant range
 number of variants
 safety and legal requirements
 production and assembly constraints
 test and quality requirements
 transport and packaging requirements
 assembly and disassembly requirements for maintenance and recycling
 requirements related to assembly operations undertaken by the user.
Guidelines for Application and Guidelines for Application and

Selection Selection
Design for assembly should, involve the following five steps at Design for assembly should, involve the following five steps at
appropriate stages of the design process (continued…). appropriate stages of the design process (continued…).
 Step 2: Check for ways of easing assembly by using
 Step 3: Embody the assemblies, interfaces and interfacing
technical opportunities in the principle solution (working
structure) and especially in the overall layout (construction elements that determine the assembly process
structure).  Step 4: Evaluate embodiment variants technically and
 Reduce the number of variants in a product range by using series economically, paying particular attention to the required
and modular construction (see Chapter 9) or by concentrating on a
few different types. interfacing procedures.
 Apply the embodiment guidelines shown in Figure 7.124 and use  Step 5: Prepare detailed assembly instructions together
these to select layouts.
with the production documents.
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References
 Pahl, G. and W. Beitz, Engineering Design–A
Systematic Approach, Springer, 2nd Ed., 1996.
DFA Guidelines
 Ease of handling and insertion is achieved by: General Guidelines
 designing so that the parts cannot become tangled or nested in each other, and 1. Minimize the total number of parts
 by designing with symmetry in mind. 2. Minimize the assembly surfaces
 Parts that do not require end-to-end orientation prior to insertion, as a screw does, 3. Use subassemblies
should be used if possible.
4. Mistake-proof the design and assembly
 Parts with complete rotational symmetry around the axis of insertion, like a washer,
are best. Guidelines for handling
 When using automatic handling it is better to make a part highly 5. Avoid separate fasteners or minimize fastener costs
asymmetric if it can-not be made symmetrical. 6. Minimize handling in assembly
 For ease of insertion, a part should be made with chamfers or recesses Guidelines for handling
for ease of alignment, and clearances should be generous to reduce the 7. Minimize assembly direction
resistance to assembly. 8. Provide unobstructed access for parts and tools
 Self-locating features are important, as is providing unobstructed 9. Maximize compliance in assembly
vision and room for hand access.
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DESIGN FOR ASSEMBLY (DFA) DESIGN FOR ASSEMBLY (DFA)

 These techniques attempt to simplify products to ease the 6. The operator will pick a part from the parts bin.
assembly process, without compromising functionality of the 7. The operators will (if not already) position the part correctly in
product.
their hand, and prepare to insert it into the work.
 First, consider the basic steps involved in assembly,
8. The operator will guide the part into the final position.
1a. parts are purchased, and put into inventory, or storage bins.
1b. parts are manufactured, and put into inventory, or storage 9. The operator will move the two parts so that they fit together
bins. 10. The operator will perform any fastening operations required.
2. batches of parts are often inspected for quality. 11. Additional alignment or quality inspection steps may
3. the batches are moved to the work station. sometimes be included.
4. the partially completed assembly may be already at the work
station, or the operator may accept it from another source Each one of these steps has potential for problems, or
(e.g., a belt on an assembly line)
improvement.
5. the part base will be set in position.
Design rule summary

Rules for Automatic Assembly
 Part Design  The basic strategies of DFA for automated assembly
1. Eliminate/minimize tangling between parts in feeders.
2. Use symmetry to reduce the orientation time during handling are,
3. If symmetry is not possible, use obvious features to speed 1. Reduce the number of parts
orientation
2. Allow assembly from the top of a fixtured part
 Product Design 3. Develop symmetry for easy part orientation
1. Reduce the number of parts when possible 4. Use guides to simplify part mating, such as chamfers
2. Build the part in layers from the top on the bottom, using gravity to
locate parts 5. Aim for snap-fit connectors, avoid screws
3. Have the already assembled product stable on the work surface
4. Have the work lie in a horizontal plane
6. Reduce handling problems
5. Use chamfers and fillets to ease mating of parts.
6. Use snap-fits, and other quick fasteners, avoid screws, glue, etc.
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Rules for Manual Assembly

 The basic rules of DFA for manual assembly are,
1. the number of parts should be reduced
2. parts should be standardized where possible
3. alignment operations should be reduced
4. locating and aligning features should be used
5. allow clear paths for parts being added to the assembly
6. add orientation features so that parts can only be assembled
in the correct orientations
7. consider part feeding/picking from batches
8. introduce symmetries to reduce the need for reorientation
9. add orientation features to simplify orientation
identification
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11/24/2017

Types of Assembly Types of Assembly

Automatic Work head

General Guidelines for Assembly General Guidelines for Assembly

General Guidelines for Assembly: General Guidelines for Assembly:

General Guidelines for Assembly: General Guidelines for Assembly:

General Guidelines for Assembly: General Guidelines for Assembly:

Designing Assembly Interfaces:

St-Storing, Ha-Handling, Po-Positioning, Jo-Joining, Ad-Adjusting, Se-Secure, In-Inspection,

Designing Assembly Interfaces: Designing Assembly Interfaces:

Designing Assembly Interfaces: Designing Assembly Interfaces:

St-Storing, Ha-Handling, Po-Positioning, Jo-Joining, Ad-Adjusting, Se-Secure, In-Inspection,

Designing Assembly Interfaces: Designing Assembly Interfaces:

Designing Assembly Interfaces: Designing Assembly Interfaces:

Designing Assembly Interfaces:

Designing Assembly Interfaces: Designing Assembly Interfaces:

St-Storing, Ha-Handling, MA-Manual Assembly, AA-Automated Assembly

Guidelines for Application and

St-Storing, Ha-Handling, MA-Manual Assembly, AA-Automated Assembly

Guidelines for Application and Guidelines for Application and

DESIGN FOR ASSEMBLY (DFA) DESIGN FOR ASSEMBLY (DFA)

Design rule summary

Rules for Manual Assembly

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