DFX原則2, 提高零件對稱性

DFX原則2, 提高零件對稱性:

(點選圖面即可放大視圖)

零件對稱性的提高,可以簡化零件在組裝前的操作(Handling),尤其是選向作業的簡化。以下分別對手工作業及自動化作業說明之。

就手工作業而言﹐零件對稱性降低或是每增加一個方向性﹐作業人員進行選向作業的作業時間會因此增加﹐同時選錯方向的機率也會增加。

上圖所示的各種外型的零件﹐除了說明零件對稱性的變化(由上而下對稱性建次減少)之外﹐更說明了Boothroyd Dewhurst Inc零件對稱性的評估方法。

基本上﹐工程人員必須在零件的組裝軸向及組裝平面上分別評估其對稱性﹐以兩端對偁的軸狀零件(如上圖中的圓柱體零件)為例﹐作業人員可能旋轉該零件0到180度後找到組裝的角度﹐此時我們給予此零件180度所謂的α選向角﹐而兩端不對偁軸狀零件(如上圖中的階梯柱體零件)為例﹐ 作業人員可能旋轉該零件0到360度後才找到組裝的角度﹐此時我們給予此零件360度α選向角。比較這兩個零件﹐可以知道作業人員在組合軸的選向作業上所需時間的可能差異﹐當然實際的作業時間差異與材料的重量﹑ 大小等因素有關﹐沒有簡單的規則可供參考﹐但是各公司可以根據公司的內部經驗﹐輕易的建立自己的工時資料庫。

關於組合平面的對稱度評估方法與軸向對稱度大同小異﹐以組合平面完全對偁的圓形零件為例﹐作業人員無須旋轉零件即可找到組裝的角度﹐此時我們給予此零件0度β選向角﹐這是對稱度的最高評價﹐表示作業人員無須作任何的選向作業即可進行組裝。再以正方柱零件為例﹐作業人員可能旋轉該零件0到90度後才找到可以組裝的角度﹐所以此零度的β選向角為90度﹐同理正三角柱零件的β選向角為120度﹐這些β選向角的大小會影響作業時間的長短。

αβ對稱性的變化除了使作業時間改變之外﹐也會使作業人員因為選向作業的增加而使作業錯誤的機會增加。因此﹐產品的設計者應該力求每個組裝零件的對稱性﹐使作業人員不但可以用極短的時間時間完成組裝﹐更可以減少組裝過程中的錯誤。

對自動化或機械人的作業而言﹐雖然所有作業有自動機械代勞﹐但是組裝零件的對稱性仍舊是其產品設計自動化組裝的易製性(Design For Automated Assy)指標。

自動化組裝系統需要一個可靠的自動送料裝置,使材料可以依照正確的方向送入待裝配的 位置﹐材料的對稱性不足除了會延長送料裝置的選向作業時間之外,甚至使選向作業成為整個組裝作業的瓶頸,降低整個自動化作業的產出量或生產力﹐這是為什麼 我們認為零件對稱性在自動化組裝產品中仍然是重要的指標的原因了!

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