Melhoria conceitual de uma comporta vagão utilizando teorias e abordagens da engenharia de projetos

Abstract

On average, 75% of the final costs of products are defined only in the Concept Design phase even in pure mechanical equipment used in small hydraulic power plants (SGP). On this paper is proposed the use of systematic approach, close with Engineering Design tools, to optimizing costs of an equipment used in SGPs, the FixedWheel Gates. Firstly, it was made a product decomposing of an Existing Gate to analyze its function, manufacturing costs and its simplified structural mechanical performance. Based on this first analysis, the Conceptual Synthesis phase began by building a generic Function Structure. In this first structure, it was identified the main subfunctions as well the flow of energy, materials, and signal. Afterword, for each subfunction, it was made one Morphological Matrix in which all Principles Solutions were ranked using the Direct Synthesis Optimization (DSO). Then, the principles that got the best rating were gather in two distinct Function Structures (FS). In the last phase of this paper, for those same FS, were used Computation Models to assist decision making. First, were designed two CAD models that work iteratively with the Finite Element Analysis until finding the points favorable or not in the Functions structures synthesized before. Lastly, it was built a final FS merging the best characteristic of the previous FS. In conclusion, it was possible to estimate a 70,4% decrease in assembling and finishing costs, 49,5% decrease in welding and 21% decrease in mass maintaining safety limits. Therefore, it was possible to conclude, by this study case, that the Conceptual Design of pure mechanical equipment is straight related to the good approach and Engineering Design tools used in the early phases in the product development.