New and innovative production equipment can be developed by introducing lightweight materials in modern day automotive industry production lines. The properties of these new materials are expected to result in improved ergonomics, energy savings, increased flexibility and more robust equipment, which in the end will result in enhanced productivity. Carbon composite materials are one such alternative that has excellent material properties. These properties are well documented, and the market for carbon composite materials is growing in many areas such as commercial aircrafts, sporting goods and wind turbines. However, when studying the use of carbon composite materials for production equipment in the automotive industry, it was found that there were few, if any, such examples. This paper focuses on innovative ways of making carbon composite materials available for designing automotive industry production equipment by introducing a design and material concept that combines flexibility, relatively low costs and high functionality. By reducing the weight by 60%, it was obvious that the operators were very positive to the new design. But just as important as the improvement of the ergonomic feature, the combination of low weight and material properties resulted in a more robust design and a more stable process of operation. The two main designs (two versions of the steelbased design were constructed) were developed sequentially, making it difficult to compare development costs since knowledge migrated from one project to the next. In this study, the gripper was manufactured in both carbon composite material and steel. The different designs were compared with reference to design costs, functionality, robustness, product costs and ergonomics. The study clearly shows that the 2 Copyright © 2013 by ASME composite material represents a favorable alternative to conventional materials, as the system combines superior properties without significantly increasing the cost of the equipment. This paper describes the approach in detail.
INTRODUCTIONTo meet new demands from industry and from customers, the manufacturer of gripper and lifting device is facing new challenges. Traditionally all grippers and fixture devices for transporting and fixing geometry in Body-in-White (BiW) are made of steel or aluminum or combinations of both, resulting in equipment that is too heavy. A second problem is that when using grippers or fixture devices in production, it occurs that they collide or fall to the ground, which results in time consuming and expensive repairs in the workshop. New and higher tolerances and lighter equipment are desired and this calls for new and lighter materials and a new way of designing them.