VIRTUAL SYSTEMS

DESIGN AND
SIMULATION FOR
PRODUCTION

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TABLE OF CONTENTS

TITLE PAGE
 Introduction…………………………………………………………............... 3

 Background…………………………………………………………………... 4

 Plan Layout…………………………………………………………………….5

 Design Method…………………………………………………………………8

 ED model………………………………………………………………………9

 Result and Discussion…………………………………………………………14

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INTRODUCTION

Virtual prototyping, also known as VP, is a software engineering discipline that involves
system modelling, simulating, visualising and improving its design via an iterative
process.Virtual prototyping technology strives to reduce time and costs and to maximise quality
and efficiency by achieving CAE (computer aided engineering) objectives. As in rapid
prototyping the technology does not require hardware to produce a prototype physically and
thus involves less cost.Today, various industries are using VP like aerospace, defence, transport
and automotive, oil and gas etc. Without building relatively expensive physical prototypes, VP
can be used to test anything from components to whole machines. In this report, virtual
designing system will be used to demonstrate the manufacturing process of sound system.

The aim of this report is to illustrate the layout and manufacturing process of the assembly of
various components of a loudspeaker. Aim of this case study is to produce loudspeakers of
good quality by keeping cost as low as possible.Target of this case study is to assemble 1
loudspeaker per 20sec.

The production and manufacturing of the loudspeaker units are very complex and high
precision is required as the market is very competitive for a business to succeed. The process
of designing and manufacturing of every part is really difficult and
evenasmall model changemay have negative consequence in the whole system. Any wrong
move in the implementation of its manufacturing can cause big losses for the company. In this
case, VP is therefore highly efficient and precise since it does not produce a physical test object
but performs these tasks in the computer, as the name suggests.

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BACKGROUND
Types of speakers
The standard dynamic speaker which we now know had first been developed in the 19th cent
ury but is connected via a magnetic field to a diaphragm to move a coil or magnet. In addition
to the standard round speaker, other types of talker / sound amplifiers are listed below:

1. Horns
Horns need no electricity to work. Horns are usually used to create irregular sounds.
The only issue with horn speakers is they cannot continuously amplify the sound. But
in today’s world, with the help of electrical amplifiers horns can generate large sounds.
Audio and Voice recording are the common uses of horns.

2. The Electrodynamics loudspeaker

Electrodynamic coils and diaphragm are used to create sound in electrodynamic

speakers. Electrodynamic speaker is modern speaker when compared to horns.
Electromagnets are used to turn the electric signals of fluctuating lengths. These
speakers are commonly used as an induction. The diaphragm vibrated due to the
electromagnetic coil and thus sound is produced with other functions. Tweeter, woofer
are some applications of this kind of speakers.

3. Flat panel speakers

Flat speakers have an exciter attached as a diaphragm to a square formed panel. It is not
possible to make the ideal flat panel speaker because the panel is not strong enough to
vibrate to the structure. Today, a number of flat panels such as electrostatic, ribbon, flat
magnetic, etc. are used.

4. Plasma arch speakers

Plasma is ionised gas, or a gas stream. Plasma is sensitive to the electrical fields and thus you
can transform an electrical signal into a plasma-manipulating electrical field. The plasma has
mass and is vibrating to produce a sound similar to how a diaphragm moves sound to air.
Visually very interesting but limited in sound quality, this type of speaker. The speaker has
problems with reliability and thus remains an innovation.

5. Piezoelectric speakers

Piezoelectric speakers use a crystal that expands and contracts to vibrate the air and
create sound. Therefore, piezoelectric speakers are constrained in frequency response
and are mainly used as tweeters or in small electrical devices such as watches / clocks

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 simple sounds. It may be possible in the future that this technology may improve,
providing a speaker with good sound characteristics and durability, however it
remains up to tomorrow’s engineers to make this possible.
Piezo electronics are a solid-state technology which makes them durable and good for
use as a microphone underwater. These speakers are used as microphones in
submarine warfare, they can detect other microphones and hear sounds of other
vessels.

PLAN LAYOUT
The loudspeakers have numerous small and complex components therein; therefore,
each of these components should be properly assembled to make a faultless speaker. Due to the small
size of components and their different nature, it is very important to arrange these parts in a perfect
order to avoid any kind of failure in the speakers. So, by the means of Virtual design system,
the components of the speakers are assembled in such a way that the sound experience is perfect. In
this project, we have chosen the electrodynamic speaker as they are best and they also work as an
induction.
each of these components should be properly assembled to make a faultless speaker

The parts of the loudspeaker are differentiated into two categories;

1. Hard Parts: The frame, plate, back plate, and magnet are called the hard parts of the
speaker. It's expensively tooling and manufacturing for small speaker companies, so
they buy them off the shelf quite a bit.

2. Soft Parts: A speaker's "soft parts" – the cone, surround, voice coil, spider – are
easier to adapt and manually put together.

Complete assembly layout followed is explained below:

 First the pole plate is fixed at the assembly layout.

 Magnet is placed is placed on the pole plate and glued to the pole plate in a
such a way that there is no gap in between them.
 Then, the top plate is introduced and is glued to the other side of the magnet so
that magnet is now covered by pole plate and top plate from both sides.
 The frame is now attached with the top plate as shown assembly in the above
is now fixed with glue and bolted tightly.
 Now the parts are introduced into the magnetization unit and heavy voltage is
utilised throughout the magnet and magnetisation is thus achieved.
 Now the spider and coil are fixed with the frame assembly by using glue
manually and soldering. The both the coil and the spider now assembled with
the frame assembly.

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  The diaphragm is then fixed to the top part of the basket and to the sound coil
with the glue such that there is no gap in between.
 Then comes the fixing of dust cap which is the last step in the assembly
layout. The dust cap is glued to the centre of diaphragm precisely.
 Now the assembly of loudspeaker is completed and it will be tested the working
under different frequencies by automated testing machine. The repairing unit
will look into the matter if any defects are found.
 So finally, loudspeaker assembly completes and it will be tested the working
under different frequencies by automated testing machine. The repairing unit
will look into the matter if any defects are found.

Assembly plan description with cycle time:

With the help of source and distribution in pole plate assemble section pole pate pass to the
assembly section to start the manufacturing with cycle time of 17s log normal. Now in the
magnet assembly section magnet glue with the pole plate with the cycle time of 19s log
normal. Similarly, cycle time for the top plate and frame is uniform 15-18s and Negexp 18s.
Here, assembly section for hard part done. After the assembly, magnetisation cycle time
taken 20s to magnetise the hard parts. Then distribute to spider coil with cycle time of
uniform 35-45s. Then its pass to the diaphragm and dust cap with cycle time of 18s and 16s.
Final automatic testing section take total cycle time of 10s for complete the process.

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PLANT CHART

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DESIGN METHOD
The speakers are two separate components, one soft and the other hard. The soft pieces
include the dust cover, the spider and the diaphragm. The hard part, however, includes the
pole, magnet, frame and top plate. All these are in the subassembly units of the engine unit.
This is the integration automation component and the soft components are assembled here.
An organisation can produce a speaker per day.
The CATIA V5 R21 was designed to build and assemble the 3D models for the speaker
components.

Here you can see in the above figure. Design and assembly sections of the components.
1) End Plate
2) Magnet
3) Top plate
4) Basket
5) Spider
6) Coil
7) Cone
8) Cap.
Design in CATIA V5 methods and tools used: -
 End plate (Pole plate): Plane- sketcher- tools circle- Parts model surface- extrude- 3d
view

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  Magnet: plane- sketcher- tools Circle- hole- parts model surface- extrude- 3d view
 Top plate: plane- sketcher- tools Circle- hole- symmetric holes- parts model surface-
extrude- 3d view
 Basket (Frame): plane- tools circle-symmetric eclipse holes- symmetric holes- parts
model surface- extrudes- 3d views.
 Spider: plane- tools circle- hole- line follow parts model surface- extrudes- 3d views.
 Coil: tools circle- plane- hole- parts model surfaces- extrudes- 3d views.
 Cone (diaphragm): plane- sketcher- circle- plane- sketcher- hole- parts model surface-
extrudes – 3d views.
 Dust cap: plane- sketcher- circle-parts model surface- extrudes- 3d views.
Final Assembly
From the above figure it shown the assemble section of the loudspeaker which is design in
Catia v5. Here end plate selected and fixed with the magnet in along symmetric axis. Now on
top of the magnet top plate connected, then basket fixed with the top plate which is tighten
with screws on symmetric axis. So here in the design hard parts ready which all are in
symmetric axis. Now soft parts need to connect with the assembly design of hard parts. So,
spider parts get connected with the hard parts of frame and top plate. Using coil which is
connected with the spider. Then Cone fixed with the frame and soldered with the coil and
magnet. Then along same axis dust cap is connected on the surface of cone. So this are the
assembly design steps which is designed in Catia V5 software.

ED MODEL
This assembly layout follows the layout process for the product. Here, all machines and
workstations are positioned according to the direction of the product flow to become
finished goods. The advantage of the product layout is that the product assembly
guarantees free flow and that the risk of product accumulation at a workstation is
minimal. In this layout, workers operating in any workstation perform only a specific task
in the entire production process, in such a way that the skill and speed of the worker
increase, which helps to increase production over time. Since the same workers perform
specific tasks, the quality of the product can also be maintained.
However, if any device / process fails in the assembly line the disadvantage of the product
layout is that the entire production process is stopped and after the failed machine the
procedure remains idle.
The above layout design is developed with the following factors in mind.
 Utilisation of Space: it is important to note that the workstation and conveyor area
does not exceed an optimal space when designing an outline. This means workers
must be able to walk openly around the production facility and that they must not
occupy a great deal of space at the same time since the initial cost could increase.

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 The design is such a way that the workers travel short distances to travel within
work area and eliminate inefficiencies.
 Cost: The upfront cost to the organisation is a major component in the selection
of the lay out. It specifies the number of machines being used and if it still
involves automated or manual processes.
 Product size: Layout conveyors can only be selected after analysis of the size of
the conveyor and the weight of the handled part. The conveyor has to be able to
carry the part causing damages to the part or the carrier itself.
 Conveyor length: The conveyor length has to be as low as possible to reduce
costs. The conveyor used in this case is 5 or 10 metres long.
 Method of transport of the final product: The mode of transport must be chosen
taking into consideration.

ED 3D model layout

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Hard Parts Assembly section

Soft Parts Assembly Section

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 Industries layout

Assembly layout (ED model)

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Product flow layout

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RESULTS AND DISCUSSION
It is found from this layout of the loudspeaker assembly that 1371 number speakers are
produced in 8 hours. Below is the summary report of the 8-hour Assembly Procedure.

content throughput stay time

name current average input output average

Product1 0 0.000 0 0 0.000

Source2 1 0.513 1403 1402 10.525
Non-Accumulation 1 0.893 1402 1401 18.337
Robot4 1 0.675 1401 1400 13.878
Non accumulation 0 1.460 833 833 50.481
Non accumulation 1 0.843 343 342 70.856
Non accumulation 2 2.040 833 831 70.530
Non accumulation 1 0.936 342 341 78.997
Non accumulation 1 0.754 126 125 171.102
Non accumulation 1 0.839 98 97 246.848
Pole plate 1 0.756 831 830 26.230
Magnet 1 0.874 954 953 26.407
Top plate 1 0.956 1050 1049 26.235
Frame 1 0.987 1389 1388 20.464
Non accumulation 1 0.701 830 829 24.350
Non accumulation 1 0.856 1049 1048 23.518
Non accumulation 0 0.768 953 953 23.224
Non accumulation 3 1.260 1388 1385 26.141
Non accumulation 3 4.203 1385 1382 87.464
Magnetisation 1 0.960 1382 1381 20.000
Non accumulation 0 0.480 1381 1381 10.000
Non accumulation 1 0.399 1381 1380 8.320
Robot23 0 0.161 1380 1380 3.363
Non accumulation 0 0.455 704 704 18.616
Non accumulation 1 0.454 676 675 19.344
Non accumulation 2 1.011 704 702 41.328
Spider and coil 1 0.970 702 701 39.790
Spider and coil 1 0.932 675 674 39.816
Non accumulation 0 0.212 674 674 9.059
Non accumulation 0 0.122 701 701 5.000
Diaphragm assem 1 0.859 1375 1374 18.000
Non accumulation 0 0.230 701 701 9.450
Non accumulation 0 0.239 1374 1374 5.000
Dust cap assemb 1 0.763 1374 1373 16.000
Non accumulation 1 0.633 1373 1372 13.277
Automated test 0 0.212 611 611 10.000
Sink38 0 0.000 1371 0 0.000
Operator39 0 0.000 0 0 0.000
Operator40 0 0.000 0 0 0.000
Operator41 0 0.000 0 0 0.000
Operator42 0 0.000 0 0 0.000
Team43 0 0.000 0 0 0.000
Operator44 0 0.000 0 0 0.000
New atom 0 0.000 0 0 0.000
Server64 0 0.226 760 760 8.575
Robot64 1 0.395 1372 1371 8.283
Operator65 0 0.000 0 0 0.000

Model start time Wednesday, May 13 2020 03:15:33

Model end time Wednesday, May 13 2020 11:15:33
Run length (seconds) 28800.00

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On a day when the assembly layout is capable of producing 1371 speakers, the working time
is 8 hours. Since one loudspeaker is sold at 5 pounds, the plant has the potential to generate
6855 pounds of revenue per day. If the plant operates 5 days a week, the potential will be
£34,275 per week. Within a year, the organisation will be able to make a potential income of
£1,713,750.
The production or assembly of speakers is not an easy task, as all the factors involved in the
process need to be perfectly handled in order to have the accuracy of the process. The
speakers' parts need to be perfectly positioned in the position of the speaker needed to
produce better sound quality.With the help of the simulation model and virtual design
software the assembly process should be planned earlier. In addition, a better assembled
speaker requires that the assembly process is handled with perfection and precision.In the
process of producing a speaker there are so many factors, and all the factors must be perfectly
maintained. Consequently, an experienced person should supervise all parts of the assembly
process to make the process efficient. All in all, the assembly process should be the perfect
way to achieve the expected result.

Evaluation of the system performance

In performance in the relevant areas the systems implemented within the organisation are highly
efficient. The system is ideal for the assembly of the speaker. In order to improve the efficiency of the
assembly process, several factors must be kept in perfect condition.

 To meet the need of the organisation, the production system must be highly efficient.
 The speaker parts must be produced with the help of the simulation model, perfectly and in a
calculated manner.
 In certain cases, the use of robots must be prominent to achieve precise assembly.
 The model of simulation should be used to estimate production time and cost in the best way
possible to avoid errors in the entire production process.
 In order to have a perfect plan appraisal and create a better diagram of the assembly
procedure, the virtual design system must be checked correctly.
 In order to support the assembly, the pre-produced parts need to be fully oriented.
 Manufacturing organisations must invest sufficient budgets in order to achieve optimal
business profit.
The design in Enterprise Dynamics of the assembly layout is helpful in estimating the initial costs of
the production unit. Problems, such as the location of workstations and workspace, can be calculated
for the workers to perform the specific tasks. The best use is the use of space, we can get an insight
into how to design the plant and how much space between the plants and the lengths of the conveyors
is needed.

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