Sustainable Manufacturing and Design

The Senior Capstone Design (SCD) Program in Mechanical Engineering builds on our lab based "hands-on" curriculum to provide students "their first job, not their last class," while helping our customers - companies, entrepreneurs, and non-profit entities - address their aggressive goals and tight budgets while providing a fresh perspective. Our teams are formed by considering student background, interests, and thinking preferences. Student teams are advised by an eight-person Advisory Team, the members of which are selected based on their technical expertise - to cover the array of typical technical needs associated with projects - and for their proven ability to guide students in solving real, applied problems. Our projects span two semesters beginning with the development of a project plan, where end-user needs, customer needs, project objectives, constraints, and metrics for success are defined. Proceeding through concept generation and selection, then through the system- and component-level design stages, each team ultimately produces a functionally demonstrative prototype that is tested and reworked toward meeting the design requirements. Projects commence in late August and early January.

Project Goal

Design and demonstrate an improved (reduced weight) POP rivet installation tool.

Background

Those familiar with the automotive assembly process and have a basic understanding of manufacturing constraints such has cycle time, repeatability, durability, and ergonomic limitations.

Need(s) Addressed

Chrysler has found an opportunity for engineering students to become exposed to the assembly environment by reviewing and redesigning components or systems of a POP rivet gun air tool. The use of rivets as an attachment mechanism is expected to increase. Also, the further an assembly plant operator has to hold the rivet tool away from the centerline of his/her body, the more the weight of the tool becomes critical. Reducing the weight of the tool even by ounces will allow the operator to hold the tool longer and will increase the repeatability of the process. Additionally, current tools do not have the ability to measure the stroke and force of the rivet while it is being strained. A modular measurement device mounted on the rivet tool should also be integrated into the design.

Project Scope

This project team will investigate lighter weight designs of components and or systems that make up a POP rivet air tool. This project will optimize current POP rivet air tool designs such that Chrysler will be able to allow the repeated use of this tool for extended periods of time. Ideally, this design can be used in multiple assembly plant on different vehicle platforms.

At the team's request the customer will provide the following:

• Detailed data defining existing tooling and known constraints

• Samples of current hardware- POP rivet guns and unused rivets

• Initial overview and definition of known issues, alternatives considered, and options available

Project Objectives

• Design, prototype, and demonstrate an updated design of a POP rivet tool. Design options considered must respect the following:

- Safety

- Design must be easy to use and WILL NOT introduce any risk while in use or being repaired

- Ergonomically easy to use

- Design must consider balance of tool

- Design must consider trigger placement

- Design must consider operator feedback for a successful shot

Reduced weight

- Design may use lighter weight materials

- Design may use weight optimized components

- Design may use few parts

- Design must be able to withstand several drops from approximately 3 feet and still function properly

The Senior Capstone Design (SCD) Program in Mechanical Engineering builds on our lab based "hands-on" curriculum to provide students "their first job, not their last class," while helping our customers - companies, entrepreneurs, and non-profit entities - address their aggressive goals and tight budgets while providing a fresh perspective. Our teams are formed by considering student background, interests, and thinking preferences. Student teams are advised by an eight-person Advisory Team, the members of which are selected based on their technical expertise - to cover the array of typical technical needs associated with projects - and for their proven ability to guide students in solving real, applied problems. Our projects span two semesters beginning with the development of a project plan, where end-user needs, customer needs, project objectives, constraints, and metrics for success are defined. Proceeding through concept generation and selection, then through the system- and component-level design stages, each team ultimately produces a functionally demonstrative prototype that is tested and reworked toward meeting the design requirements. Projects commence in late August and early January.

Project Description

Design, engineer, build, and test a new carbon fiber lightweight tailgate with an aluminum sub-structure. The first goal is to save a minimum of 25% weight over the current steel design. Additional goal will be to incorporate a unique selling feature into the design of the gate that provides an alternative function of the tailgate that can be marketed. Intent is to create a product that can be used for a limited volume high performance vehicle or eco fuel-efficient package.

Background

The Dodge Ram full size pickup is a very important vehicle for Chrysler Corporation and is considered one of the primary pillars and major profit generators. The truck is very popular in a wide variety of markets from personal use to commercial applications. Two plants currently build the RAM truck with volume exceeding 300,000 units per year (Warren Truck Assembly Plant and Saltillo Assembly Plant). The push for improved fuel economy is driving the company to look for ways to save weight while maintaining the functionality that the customer has come to expect. This project is intended to create what is called a "buzz" model, which is limited in volume (5000 units), is aspirational, and contains features not normally available in other mainstream vehicles. Carbon Fiber is a very high tech material and its appearance on the exterior of the truck communicates a perception of performance equivalent to high-end sports cars. It provides outstanding strength to-weight ratio, which will provide a solid platform to save mass. In addition to simply saving weight, the goal of the team is to develop a unique selling feature designed into the tailgate. Some ideas that have been discussed are an integrated barbeque, storage compartment, fold out table, step assist. There have even been really creative ideas such as a fish cleaning station, or clay pigeon throwing mechanism. Bottom line is the team will need to brainstorm different ideas that would be marketable to a specific segment of the population and design the feature into the tailgate.

Need(s) Addressed

Excess mass in any motor vehicle today relates directly to fuel inefficiency. It is critical for carmakers today to minimize any mass in the vehicle that is not necessary. The current steel design of the Tailgate weighs 60 pounds. The goal of this project is to save a minimum of 25%

(15 lbs) while being manufacturable, production-viable, cost efficient, and meet all structural and customer performance requirements as outlined in the design validation plan (DVP&R).

Additionally, incorporate an alternative function into the Tailgate as previously described and demonstrate its function. The team will need to develop appropriate tests for whatever feature is decided on to ensure all range of customer usage can be done robustly without failure.

Project Scope

This design project will focus on designing and developing a lightweight tailgate concept that meets the customer functional objectives and amazes them with dual-purpose function. In general, the swing gate must:

• Meet all static and dynamic load cases as specified in DVP&R.

• Contain design provisions for use of existing hardware (latch/striker, handles etc).

• 25% lighter than current design.

• Production manufacturable using available processes.

• Cost efficient such that business case is positive and tooling is paid for in 1 year.

Confidential