DFX可制造可装配设计

制造设计与装配设计

Designfor

Manufactureand

Assembly制造设计与装配设计

DesignforManufacture&Assembly制造设计DesignforManufacture设计易于制造的零件

Designthecomponentpartsthatformtheproductforeaseofmanufacture装配设计DesignforAssembly设计易于装配的产品

Designtheproductforeaseofassembly参考构成产品的更多零件或连接件

Referstotheadditionorjoiningofpartstoformthecompletedproduct制造设计与装配设计

DesignforManufacture&Assembly手工装配设计Designformanualassembly电子连接器与线束装配Electricalconnectorsandwireharnessassembly高速自动化装配与机器人装配High-speedautomaticassemblyandrobotassembly印刷线路版Printedcircuitboard机加工Machining注塑Injectionmolding金属板材Sheetmetal浇铸Die-casting粉末冶金加工Powdermetalprocessing设计的连续性DesignContinuum制造设计与装配设计

Designformanufactureandassembly可维护性

Serviceability可循环性

Recycling制造设计与装配设计的优点

AdvantagesofDesignforManufacture&Assembly简化产品

Resultsinsimplerproducts鼓励设计者与制造工程师进行对话

Encouragesdialoguebetweendesignersandmanufacturingengineers大大节省劳动力与物料成本

Achievessignificantsavingsinlaborandmaterials促进精益制造

Enhancesleanmanufacturing设计要素DesignElements装配设计Designforassembly制造设计Designformanufacture选择物料与流程Selectionofmaterialsandprocesses详细的样机Detailedprototype流程简介ProcessOverview装配设计DesignforAssembly减少使用独特零件的数量

Reducethenumberofuniquepartsintheassemblydesign将易于装配作为设计指引

Usedesignguidelinesforeaseofassembly减少独特零件的数量

ReducetheNumberofUniqueParts零件间必须相互移动吗?

Mustthepartmoverelativetootherpartsalreadyinstalledintheassembly?零件要用不同材料制造吗?

Mustthepartbemadeofdifferentmaterial?零件必须相互隔开吗?

Mustthepartbeseparatefromotherparts?装配设计前“线性可变差分变压器”组件

LVDTAssemblyBeforeDesign支柱螺丝Stand-offScrews变压器(外购组件)LVDT

(PurchasedAssembly)支柱(机加工件，钢)LVDTStand-offs(MachinedSteel)外壳(焊接件，钢)LVDTCover(WeldedSteel)外壳螺丝Cover

Screws底座(机加工件，铝)LVDTBase(Machined

Aluminum)盖板(塑胶)EndPlateSheet(Plastic)举例：

LVDT组件Example:LVDTAssembly(装配设计前)(Before)零件Part零件数量PartQuantity底座LVDTBase1变压器LVDT1支柱StandOffs4支柱螺丝StandOffScrews4盖板EndPlate1外壳Cover1外壳螺丝CoverScrews4每个组件零件总数TotalPartsperAssembly16Part零件零件数量PartQuantity

(装配设计前)

(Before)零件数量(理论上)PartQuantity–

Theoretical

(装配设计后)(After)底座LVDTBase11变压器LVDT11支柱StandOffs40支柱螺丝StandOffScrews40盖板EndPlate10外壳Cover11外壳螺丝CoverScrews40每个组件零件总数TotalPartsperAssembly163(装配设计后)(After)举例：

LVDT组件Example:LVDTAssembly装配设计后的LVDT组件

LVDTAssemblyAfterDesign变压器(外购组件)LVDT(Purchased

Assembly)底座LVDTBase外壳(注塑件)Cover

(Injection

Molded)3339设计评审零件数量最少零件测试移动物料分开理论零件数量装配时间原设计新设计设计指数DesignIndex

理论装配时间Theoreticalassemblytime

%设计效率Designefficiency=

实际装配时间Actualassemblytimex100=理论最少零件数Theoreticalminimum#ofpartsx3理论装配时间Theoreticalassemblytimex100

实际Actual–最少Minimum

%减少零件之可能性Partsreductionpotential=

实际零件数量Actual#ofparts设计评审减少零件的潜力设计效率易于装配指引GuidelinesforEaseofAssembly零件呈送Partspresentation零件搬运Parthandling零件插入Partsinsertion零件紧固Partsfastening产品变化Productvariation零件呈送指引GuidelinesForPartsPresentation防止堵塞与纠缠

Designoutjammingandtangling避免过大或过小

Avoidtoosmallortoolarge两端尽量要对称

Designforend-to-endsymmetry沿插入方向旋转对称

Designforrotationalsymmetryaroundtheinsertionaxis防止纠缠DesignOutTangling防止相互连接DesignOutInterconnecting防止套住DesignOutNesting避免使用要精确放置的小零件

AvoidSmallItemsRequiringPrecisionPlacement对称设计DesignForPartSymmetry零件搬运考虑因素PartHandlingConsiderations尺寸Size厚度Thickness套住Nesting重量Weight纠缠Tangles易碎Fragile易滑Slippery易粘Sticky要双手处理Requirestwohands要抓取工具Requiresgraspingtool要放大才看得见Requiresmagnificationtobeseen要机械辅助Requiresmechanicalassistance零件设计成带承滴面

DesignPartsWithDrippingSurfaces零件插入指引GuidelinesForPartInsertion插入零件阻力要小

Designforminimalresistancetoinsertion采用非对称设计，保证插入零件时正确定向

Useasymmetricaldesigntoensurecorrectpartorientationuponinsertion避免半成品重新定位–最好能垂直装配(尽量沿一条轴装配)

Avoidtheneedtorepositionapartially-completedassembly—designforverticalassembly(ononeaxis,ifpossible)避免装配时要往下拿住零件才能定位

Avoiddesignsthatrequireholdingpartsdowntomaintainorientationduringassembly先定位，后松开

Designpartssothattheyarelocatedbeforetheyarereleased最小阻力设计DesignForMinimalResistance确保正确定位EnsureProperOrientation避免装配时重新定位

AvoidReorientationDuringAssembly垂直式、单轴式装配Vertical,One-AxisAssembly避免要固定零件才能定位

AvoidHoldingPartsToMaintainOrientation先定位，后松开

PartsAreLocatedBeforeTheyAreReleased先定位，后松开

PartsAreLocatedBeforeTheyAreReleased零件紧固指引GuidelinesForPartFastening使用机械式紧固件时，尽量使用最低成本的方法：

Whenusingmechanicalfasteners,attempttousethelowestcostmethod:按扣式固定Snapfitting塑胶弹性固定Plasticflexing铆钉固定Riveting螺丝固定Screwing所有型号、所有生产线的零件、流程、方法都标准化

Standardizeoncommonparts,processes,andmethodsacrossallmodelsandproductlines.紧固件设计DesignIntheFastener使用按扣式设计Use“SnapTogether”Designs紧固件标准化StandardizeFasteners产品变化ProductVariation型号差异与灵活性

Planmodeldifferentiationandflexibility模块化

Modularity在生产线末才决定型号

Modeldeterminationatendofline简化每天生产不同型号之要求

Simplifycapabilitytobuildanymodelandday减少仓存单位数量

ReducednumberofSKU’s零件的通用与再用

Common/re-useofparts其它指引MiscellaneousGuidelines避免使用连接

Avoidconnections避免难以操作

Eliminaterestrictedaccessforoperations避免需要调整

Avoidadjustments减少零件差异

Minimizepartvariation避免使用连接AvoidConnections避免难以操作EliminateRestrictedAccess最佳设计TheBestDesign简单化–机器人都可以完成

Simple-evenforarobot不用看或单个手都可以操作

Blindfolded,one–armedoperator“最佳的设计就是可行而最简单的设计。”

-阿尔伯特•爱因斯坦“Thebestdesignisthesimplestdesignthatworks.” –AlbertEinstein制造设计的概念DFMConcepts减少零件Partsreductionstrategy原料选择Rawmaterialchoices防错设计Mistake-proofdesigns六西格玛制程能力设计Designfor6sigmaprocesscapability加工Processing物料Material工模Tooling装配Assembly最低总成本设计DesignForLowestTotalCost少零件

最佳设计FewerParts

BestDesignStrategy原料决定流程

RawMaterialChoicesLeadtoProcessDecisions零件装配ComponentAssembly用整块料加工MachinedFromSolid成型Formed铸造Cast?锻造Forged?粉末冶金PowderedMetal?厚度统一CommonizeThickness使用标准的库存尺寸UtilizeStandardStockSizes.250.263直径1/2”dia直径