Co-locating one of our engineers with our customer's engineers allowed us
to cut design time for a four-piece Kenworth T2000 truck instrument panel and
glovebox assembly from the industry-standard 36 to 48 weeks to just 26 weeks.
The reason: Our project manager, Dave Wix, could provide molding guidance to the
customer immediately on a feature-by-feature basis, rather than waiting weeks to
review multiple design changes.
Among the major challenges of the project were the panel's complex geometry--including ribs, bosses, and variable cross sections--and strict material-performance requirements. The truck's windshield, with the steepest slope in the industry, made quantification of the thermal conditions and environment difficult.
In solving these problems, we developed a new molding process called TRIMTM that we believe provides more design flexibility and thermal-mechanical performance.
Software aids design. For the vehicle's interior components, Kenworth required that we minimize instrument-panel weight, maximize strength, and create the internal volume for HVAC ducting, fuse boxes, wires and harnesses, and gauges. We realized that connections between the four molded parts would have to be designed to optimize the upper and lower tab/flange thickness on the middle of the instrument-panel part. The most conservative assumption was that the required 6g load in the aft section would act completely on the middle instrument panel and glovebox assembly, since the horizontal nature of the loading would translate directly through the upper and lower instrument-panel parts.
We used ANSYS finite element analysis software to determine the appropriate material thickness.
Material development. Kenworth required that the panel achieve a heat deflection temperature (HDT) of &160F at 66-psi loading. Additionally, the coefficient of linear thermal expansion (CLTE) had to be &3.0x10-5 in/in/degree F.
To meet those requirements, Tempress and BASF jointly developed a design of experiments (DOE) using a Taguchi Lorthogonal array. Actual test results exceeded our expectations.
Results from another test led us to change material formulations to improve impact properties and nearly double elongation before failure with no appreciable loss of other properties.
Perhaps the biggest benefit to Kenworth was the addition of multifunctional ribs and bosses inside the instrument panel. They aid in registration and assembly of HVAC ducting, sheet-metal bracketry, fuse boxes, and routing of electrical wires and harnesses. Including all those features on the molded product eliminated components and minimized processing cost.
Design and develop a vinyl-clad reinforced urethane instrument panel and glovebox assembly. Heat deflection temperature: &160F at 66-psi loading. Coefficient of linear thermal expansion: &3.0×10-5 in/in/degree F.
Windshield slope, steepest in the market, made quantification of thermal conditions difficult.
Abusive environment for trucks, and Kenworth's 1,000,000-mile reliability requirement.
Parts for the 6-ft-long, 2-ft-high, 2-ft-deep assembly had to be lightweight, as follows: Urethane surface top, 7.71 lb; middle, 3.0 lb; lower, 7.1 lb; glovebox, 0.8 lb. Vinyl surface top, 12.5 lb; middle 5.4 lb, lower, 11.3 lb, glovebox, 1.7 lb.
Accommodating growth and shrinkage among engineering materials from RIM thermosets to steel, aluminum, thermoplastics, and others.
Kenworth's desire for soft yet durable vinyl exterior on urethane RIM parts.
Uniform density and reinforcement additive distribution across molded parts.
QS 9000/ISO 9000 requirements.
Integration of new CAD system at Kenworth.
Design tools/ suppliers
Pro/ENGINEER CAD software from Parametric Technology Inc.
ANVIL 5000 CAD software from MCS Inc.
Silicon Graphics workstations
IBM RS6000 workstations
ANSYS finite element analysis software from ANSYS Inc.
Truchard will be presented the award at the 2014 Golden Mousetrap Awards ceremony during the co-located events Pacific Design & Manufacturing, MD&M West, WestPack, PLASTEC West, Electronics West, ATX West, and AeroCon.
Robots that walk have come a long way from simple barebones walking machines or pairs of legs without an upper body and head. Much of the research these days focuses on making more humanoid robots. But they are not all created equal.
The IEEE Computer Society has named the top 10 trends for 2014. You can expect the convergence of cloud computing and mobile devices, advances in health care data and devices, as well as privacy issues in social media to make the headlines. And 3D printing came out of nowhere to make a big splash.
For industrial control applications, or even a simple assembly line, that machine can go almost 24/7 without a break. But what happens when the task is a little more complex? That’s where the “smart” machine would come in. The smart machine is one that has some simple (or complex in some cases) processing capability to be able to adapt to changing conditions. Such machines are suited for a host of applications, including automotive, aerospace, defense, medical, computers and electronics, telecommunications, consumer goods, and so on. This discussion will examine what’s possible with smart machines, and what tradeoffs need to be made to implement such a solution.