Omkonstruktion av bockverktyg : Från hydraulisk till elektrisk drivning

Sammanfattning: A hydraulic bending tool is used in the manufacturing of transformer windings at Hitachi ABB Power Grids. This tool is used to create a pitch between the turns in the winding, a process which demands very strict tolerances during bending. Hitachi/ABB believes that the current tool is quite inconvenient and, in some cases, dangerous to use. This is due to the tool's hydraulic hoses which causes potential risks of tripping and a risk of leaking pressurized hydraulic fluid. A potential solution to this problem was identified to be a redesign of the tool where the hydraulic system is replaced by an electrical system with batteries as the power source. Using interviews, experiments and literature reviews, user and product requirements specifications were formulated. These laid the foundation for the concept generation that followed where concepts were developed for different parts of the tool. These concepts were evaluated and then passed on to a concept combination matrix where different configurations were developed. The configurations were scored in a Pugh matrix which ultimately led to a final concept choice. This concept was then further developed with appropriate calculations and investigations, as well as a complete 3D-CAD modeling. The result was a complete solution that was equipped with batteries, an electro-hydraulic actuator as well as a control system for the stroke of the actuator. Evaluation of the tool’s performance and weight as well as cost calculations were made to compare the new design with the old one. The battery-powered bending tool proved to be a good replacement for the hydraulic bending tool. The weight and price increased slightly compared to the old one, but it was considered that the new tool generally fulfilled the needs and requirements that were presented in the beginning of the study.