Modulaarse piirdesüsteemi väljatöötamine ettevõttes alumetallgrupp oü

Käesoleva lõputöö baasettevõte on metallkonstruktsioonide tootmisele orienteeritud ning tegelenud ka alumiinium konstruktsiooniga kaitsepiirete edasimüümise ning paigaldamisega aastaid. Kogunenud kogemuste põhjal kujunenud visioon omatootest teostati tootearendusliku ülesandena autori poolt, mille arendusprotsessi käsitletav dokument kirjeldab, kus omatoote kujundamisel on arvestatud ettevõtte poolt seatud tingimusi ning välja selgitatud, konkreetset toodet puudutavad, eksport riikides sätestatud määrused ja kehtivad standardid. Kirjeldatav toode, modulaarne piirdesüsteem, kujunes suuruselt 1200mm kõrguseks piirdeks mis moodustub moodulitest. Moodulid koosnevad posti komplektist ja paneelist milleks on karastatud ja lamineeritud klaas. Posti komplekti kuuluvad: erikujuga alumiinium profiil post, roostevaba terasest tald, erikujuga tihendid ja kork, distantsklots ning katteliist. Profiili ristlõige on kujundatud lähtuvalt määrustes sätestatud, maksimaalsest lubatud, läbipaindest (20mm) arvestades ka piirde kogu kõrgusest tingitud posti pikkust. Piirde süsteemile rakendatav joonkoormus 1,5kN/m on arvutustes taandatud postile, kus 1,5kN jõu juures oli FEM analüüsi tulemus 19,98mm. FEM tulemus on kontrollitud ka käsiarvutusega mis kinnitab analüüsi tõesust, sest käsiarvutus on samas suurusjärgus tulemusega 19,99mm. Kalkulatsioon läbipaindele on kriitilisele piirile ligidal, sellest tulenvalt on võrreldud ka materjali, standardis spetsifitseeritud, omadusi reaalsete tõmbekatsete tulemustega. Tõmbekatsetest on järeldatav, et materjali AWEN-6063 T6 reaalsed omadused on ~20MPa suuremad standardis sätestatud miinimumist. Ühtlasi on ka FEM analüüsis määratud omadused võrdsed minimaalsete omadustega. Varu läbipaindele on materjali omaduses, kuigi ka minimaalse omaduse esinemisel jääb piirde lubatud läbipaine arvutuslikult alla kriitilise piiri. Küll aga iga partii mis tarnitakse läbib kvaliteedi kontrollimisel ka tõmbekatsed ning kui selgunud omaduste alusel esineb kahtlus, teostatakse ka läbipainde 1:1 katsetus. Moodulis kasutatava karastatud ja lamineeritud klaasi paksus on valitud 8mm. Mis on saadud sihtriigis kehtivast määrusest, klaaspaneeli suurusi lähtuvalt kinnitusviisist sätestavast tabelist. Määratletud, karastatud ja lamineeritud, paneelide valikust on moodulis kasutatav paneel arvutuslikult ka majanduslikult efektiivseim. Käsitletud majanduslikes olukordades, arvutusliku realiseerimis hinnaga on kirjeldatav toode majanduslikult efektiivne nii proovipartiide näidetel kui ka planeeritava, optimeeritud 26,78% efektiivsema tootmise juures. Investeeringu tasuvus on mõlemal juhul saavutatav, ümardatult ~350 mooduli müügiga. Edasiste tegevustena ettevõttes on planeeritud taotleda tootele CE märgist, luua vastav tootmisliin ning arendada järgmisi tooteid, kasutades ka käsitletava toote puhul rakendatud profiile, et ettevõtte pakutavat nomenklatuuri suurendada.

Company Alu Metall Grupp OÜ based development of modular railing system Current thesis describes a specific product that was developed in a company. Named company has years of experience from installing modular railing systems, previously, has previously placed competitive products. Hence an idea for own product development was generated. This approach was proved by first calculations to be economically a lot more efficient than previously when buying and installing existing systems, so a decision by the board of the company was made and the actual development process was started. To ultimately finish the development of a product, which is described in the thesis, successfully, next nuances should be taken into consideration: accordance to requirements that are presented in the export country’s regulations and standards, conformity to demands, regarding properties and appearance. Hence previous, it was important to ascertain allowed sag at determined height of the railing and applied forces in test conditions. Recommended thickness of the glass at established conditions, suitability for weather conditions and other precepts affecting the dimensions. Set development task, described in this document, was executed by the author. During the modeling of the product, company demands were taken into consideration, as well as identified valid standards and set regulations in export countries. Described product, the modular railing system, turned out to be 1200mm in height. The module consists of a border pole kit and a tempered & laminated glass pane which forms a border between poles. These elements are included into the border pole kit: an aluminum pole profile which has a unique cross-section shape, a stainless steel sole, a specially shaped seal, a profile cap, a distance spacer and a covering slat. Aluminum pole is designed based on stated regulations, maximum allowed sag while considering lever length from total height of the railing system. Applied force on whole railing is 1,5kN/m but in calculation it is reduced on poles, what makes 1,5kN force per pole. Result of executed FEM analysis in described conditions were 19,98mm. Mentioned result is double checked by hand calculations, what gave the result of 19,99mm conjointly proves FEM result to be true. Calculations on sag are critically close to allowed maximum, hence material properties have been compared. Properties specified in ISO standard have been compared to factual tensile test results. Conclusion of tensile tests is that material AWEN-6063 T6 actual properties are ~20MPa bigger than minimum value stated in standard. Also properties applied in FEM analysis were equal to minimum, stated in standard. Therefore spare for sag is in material properties, although at minimum material properties, according to calculations, sag will stay under allowed maximum. However, every batch that is supplied goes through quality control which involves a tensile test as well, and if based on actual properties a suspicion occurs, 1:1 sag test will be carried out. Tempered & laminated glass pane, used in railing module, thickness chosen is 8mm. This thickness is chosen based on sizes which depend on the way it is mounted. These values are stated in a regulation that are valid in the export country. The chosen glass pane, according to calculations, proved to be economically the most efficient as well when compared to other suggestions stated in mentioned regulation. Test batch, as well as planned manufacturing line, proved to be economically beneficial for the company in both situations with calculated selling price. Optimized manufacturing will be 26,78% more cost-effective compared to test batches. Both investments will break even at around 350 modules of railing sold. Further activities regarding the described product are to apply it for CE mark, to create a corresponding manufacturing line and to develop new products, where the same, already made unique profiles can be used to increase nomenclature of products offered by enterprise.