Multimethodology based on Design-to-Value (DtV), integrated with simulation techniques and prioritization of teamwork for the optimization of a pneumatic rack & pinion actuator

The investigations here presented focus on the redesign and innovation of a pneumatic rack and pinion actuator for valve actuation, as a case study for investigating the potential of a multimethodology based on the Design to Value (DtoV) process, coupled with design techniques utilizing FEA simulations and giving high priority to teamwork. The final objective of this case study is to show how it is possible to optimize the design, increasing weight efficiency while maintaining performance, and to simplify it, with a reduction of components construction complexity, according to the growing demand for a lean production. The principle that guided all the activities was valorizing the power of teamwork, focusing the team on Safety and Reliability. In an initial phase, all the instruments foreseen by “Design-to-Value” process have been applied, obtaining a classification of the contents of the product constituting its sources of value. Subsequent outputs are proposals for efficient construction solutions, driving a second phase, dedicated to the re-design of the actuator. The peculiarity of this project has been to combine the "Design by Formulas" techniques with advanced FEA simulations ("Design by Analysis"), aiming to stress, deformation, and topology optimization. A two-step experimental validation is used, based on a preliminary "mockup" prototype followed by a complete detailed prototype, for confirming the results of the calculations and simulations, by directly performing a series of in-depth tests. Preliminary obtained results show that the approach based on the described multimethodology, makes it possible to optimize the design of the actuator, maintaining safety, reliability, and performance. In the case studied, the weight reduction is expected to be 8% and economic efficiency increase is expected to be near 20%.