PRODUCT DEVELOPMENT OF ROOM AIR-CONDITIONERS USING SOLID EDGE

1. Solid Edge Second Annual International User Group Conference October 14, 1999 PRODUCT DEVELOPMENT OFROOM AIR-CONDITIONERS USING SOLID EDGE Takashi MIYAWAKI miyawaki@cae.daikin.co.jp Daikin Industries Limited Information Technology Advancement Center

2. Overview of DAIKIN http://www.star-net.or.jp/daikin/index_e.html Company Profile • Number of Employees : About 8000 • 1 Head Office and 4 Branch offices • 5 Manufacturing Plants • Related Company：61 in Japan, 14 in the World (Belgian, Thailand, etc..) • Main Products • Air-conditioners and the Applications • Fluorine Chemical products • Computer Hardware and Software Sales Air-conditioners for Store and Building Room Air-conditioners Example of Air-conditioners

3. History of Three Dimensional CAD Advancement in DAIKIN and Purpose of This Trial Project • First Step : Introduction Term (Up to the present) • In order to apply three dimensional CAD to Air-conditioner’s piping design, system development using Pro/E was started from 1991. • Trial use and improvement of the system until 1994. • Release to user from 1995, and now it is used in the almost of main developments of air-conditioners outdoor units. • Second Step : For real use Term (Now) • To enlarge the effectiveness of 3D Design, change the direction to full 3D design and start to reevaluate the 3D CAD system from 1997. • Evaluation point : Ease of use, Well-balanced function of 2D and 3D,and Cost • Solid Edge was selected best one of next CAD in June 1998. Purpose of This Trial Project Verification of Solid Edge Function by Practical use in the product development

4. Details of Verification • Function verification • Function of 3D design for Air-conditioners • Performance speed • Reliability • Utility Verification • Decrease of learning time than the system before • 3D design of large and complex plastic parts in the real development • Effectiveness Verification of 3D design • Accuracy improvement of design, and Decrease of design time • Reduction of processing time of trial manufacture • Time Reduction of mold design

5. Overview of Solid Edge Trial Project- Application to Product Development of Room Air-conditioners - • Features of Target Product • Drastic cost-cutting: new type of shape/structure should be developed • Faster development by two months 3-D Design was the only solution • Action Overview • Consists of 200 parts • Including 5 very large parts: 1500 dimensions each • Four to five designers are working in a team • Using Solid Edge over the entire design process: Conceptual Design through Generating Production Drawings Room Air-conditioners Image (Previous Model)

6. Theme in Applying 3-D Design • Effective modeling of Large and Complex plastic parts • Characteristics of Feature base modeler • Advantage : Make the design efficient, Information Transmission of design Intent • Effective Approach in Series Design and Appropriation Design • Transmit design intent correctly • Avoid stupid mistake • Problem : Handling of Large Part Features • It takes a lot of time for searching and recalculating when feature editing Establish of Efficient Three Dimensional Modeling Skill for Feature based Modeler Suggestion of Function Based Modeling and Implementation

7. About Function Based Modeling • Modeling by functional character rather than geometric • Large and Complex parts are multi-functional • structure could be simple and applicable to other models by dividing by function • functions are usually to contain something • air duct : contain air, drain-pan : receive water • Basic consideration • divide into parts by function and unit to be made shell • rough shaping to start • editing by cut/add should be done before shelling

8. Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Feature Parallel Approach and Sequential Approach of Function Based Modeling • Parallel Approach • making parts and integration by linking with Assemble Layout • grouping by function • Sequential Approach • sequential Link by Divide Parts or Insert Parts • grouping by modeling level Parallel Approach Sequential Approach Desired Part Insertion for Integration Part Part Part Desired Part Assembly Layout Assembly Insertion Insertion Function Part Function Part Function Part Control of Shape Feature Feature Feature

9. Function : Utility : Effectiveness : Implementation Result 1 : Concept Design by Solid Edge Existing product Integration two parts into one and It is difficult to design by 2D Rapid Prototype Concept Design by Solid Edge Data Transfer by e-mail 6 Days for processing （1/2 time） Result in Concept Design 6.5 days for modeling include OJT(On the Job Training) 1/2 time compare to 2D design

10. Implementation Result 2 : Detail Design by Solid Edge Heat Exchanger Assembly Fan Assembly Frame Assembly Air clean unit Air flow Assembly Electric Component Assembly Front Panel Assembly Two kind of front panel Learning Time 2 or 3 days for basic 2 weeks for practical use

11. Implementation Example of FBM (Function Based Modeling)- Parallel Approach on Frame Part - Divide into parts as air path, motor cover, fix part on back face, drain pan, etc Integration to one part by assembly insert

12. Frame Part by FBM: Part Linkage with Assembly Layout Generate parts by “Create In-place”, and Linking with Assemble Layout.

13. Frame Part by FBM: Correspondence to Design Modification Shape modification before shelling

14. Frame Part by FBM: Shape Coordination after Integration Screw boss : prepared longer than required as functional part. After assembled, protrusion is cut by Replace Face

15. Example 2:Front Panel Parts- Parallel and Sequential approach -

16. Front Panel Parts by FBM: Industrial Design Surface • Industrial Designer Integrate them by insertion to a part, and divide the part into two parts using Divide by face Modeled the right half of outside shape of Front Panel Generate the other side by Insert Part and Mirroring Completion ofPanel Face

17. Front Panel Parts by FBM: Detail Modeling 1 Feature grouping was done by Integration, Division, and Part insertion(FBM sequential approach) Detail Modeling (Outside) Detail Modeling (Inside)

18. Front Panel Parts by FBM: Detail Modeling 2 • Designer Divide Part into upper slit portion and rollet portion (when Patterning is included, other operations tend to becomes abnormally slow.)

19. Front Panel Parts by FBM: Detail Modeling 3 Right and Left covers Almost symmetric each other but have slight difference applied Family of Parts ( with Suppress Feature)

20. Front Panel Parts by FBM: Integration to one Part Integrate into one part (FBM parallel approach)

21. Effect of Three Dimensional Surface Modeling Two types of panels are designed. Shape parameters are defined using parametric dimensions in Solid Edge. Not coordinate here Shape modified on the Screen Avoid mistake which will occur in case of two dimensional design

22. Whole Image of the Product

23. Result of Direct and Rapid Prototype from 3D Model • Effect • Realization of Drawing Less and Data Transfer by Internet • Panel Parts : Accurate and Time Eliminate by NC Processing. Omission of ID Model making. • Electric Component : Rapid Prototypes are very effective in these parts (small and complex) • Inquiries from processors about model are Almost nothing • Subject • Rapid Prototype for Large Part like Frame (Accuracy and Strength is not enough for test model) • It is difficult to transfer the modification portion when alternation because there is no drawing • Prototype is made the same shape as 3D model even if there is a mistake (No check before prototype) -> Strong evaluation of 3D model before trial is needed Comparison between 2D and 3D about Front Panel Parts ２Ｄ Prototype making Modification of mistake Design Drawing Alternation Inquire Accuracy Improvement ３Ｄ Design Alternation Prototype making Inquires Decrease

24. 最後に • 今回のプロジェクトで多くのサポートを頂き、またこのような発表の機会を与えていただいたユニグラフィックスソリューションの方々にお礼を申し上げます。 • 特にダイキンの要望を理解していただき、機能の実現をしていただいたDavid Hagood氏、また技術的な質問の受け答えから米国とのやりとりを含め各種の辛抱強いサポートを頂いた原さんに感謝します。