Chalmers Open Digital Repository

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  • Studentarbeten utgivna på lärosätet, såväl kandidatarbeten som examensarbeten på grund- och masternivå
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Senast publicerade

  • Conceptual Design of a Next-Generation Wire Harness Assembly Workstation for Industry 5.0
    (2026) Carlsson, Johan; Sekar Vasanthi, Arvind Navin
    This thesis presents a conceptual design for the next generation of wire harness assembly workstations at Volvo Cars. With the manufacturing industry shifting toward Industry 5.0, the primary objective of this research was to develop a realistic, efficient, and flexible assembly solution capable of being implemented within a 5 to 10-year timeframe. Through a comprehensive literature review, interviews with industry stakeholders, and a detailed requirement analysis, this study evaluates the integration of Automated Guided Vehicles (AGVs) and collaborative robots (cobots) as a viable strategy to enhance production performance. The proposed solution emphasizes a gradual transition toward increased automation, where cobots and AGVs are integrated directly into the wire harness workstation to support operators, improve ergonomics, and stabilize material flow. The simulation assessment was used to evaluate the proposed workstation layout, movement sequences, approximate cobot reach, and compatibility with the existing line speed. In addition, the concept includes an AI-based automated quality control system integrated into the wire-harness workstation. The system is intended to support inspection of routing, component presence and variant correctness immediately after assembly tasks are completed. The findings suggest that the role of the human operator will evolve from performing repetitive manual labor to assuming more high-level responsibilities, such as system management, operational oversight and complex problem-solving. By retaining human expertise for scenarios requiring specialized judgment, the proposed design achieves a balanced synergy between advanced automation and human-centric manufacturing. This research provides a structured roadmap for Volvo Cars to modernize its production facilities, ensuring long-term competitiveness and operational efficiency
  • Hjälpmedel för ergonomisk montering i specialombyggda fordon
    (2026) Olofsson, Victor; Kindberg, Victor; Ericsson, Oscar; Hotlmann, Vilgot; Lindgren, Rickard; Betsgren, Anton
    This bachelor thesis was conducted with the aim of improving ergonomics and reducing the physical strain experienced by assemblers at Nordic Vehicle Conversion. The project specifically addressed the lifting and installation of passenger seats and stretcher bases during the assembly process. The product development process was carried out iteratively in several phases, based on a framework designed to provide structure without limiting innovation. Continuous refinement through feedback was a central aspect throughout the project. Ultimately, the work resulted in two proposed solutions. The first solution concerns the handling of passenger seats and consists of an electric pallet stacker combined with a specially designed pallet. Together, these enable an efficient and ergonomically sustainable method for lifting and positioning the seats. The second solution consists of a crane system with an associated strap mechanism that enables the precise lifting and placement of stretcher bases. By implementing these solutions, most manual lifting operations within the assembly process can be eliminated, leading to improved ergonomics and a better working environment for the assemblers
  • Hejlo – barnens egna hemtelefon Konceptframtagning av barntelefon för användning i hemmet
    (2026) Bergman, Sonja; Gavelin, Amanda; Gylseth, May; Louise, Arado Lindström; Thörsman, Ida
    This project explores the development of a concept for a home-based communication device designed for children aged 5–9 years. It addresses the increasing exposure of children to smartphones and digital media, and the associated challenges related to screen time, well-being, and parental concerns. A user-centered and iterative design process was implemented, combining both qualitative and quantitative methods such as interviews, surveys, observations and user testing. Through these methods user needs and requirements were identified and translated into a design concept. The result is a communication device focused on interaction by voice. This enables children to communicate with selected contacts without an access to the internet or social media. The concept is integrating features of parental control such as a way to verify contacts and regulate time of usage to ensure safety while supporting a childs independence. The project demonstrates that it is possible to design an alternative communication solution that balances simplicity, safety, and usability. This, while meeting the needs of both children and parents.
  • Simulation Analysis of Ceramic Shell Representation and Process Parameters in IN718 Investment Casting
    (2026) Andersson , Joel
    This thesis investigates how ceramic shell representation and selected process parameters influence the simulated solidification behaviour and predicted defect tendency of an investment-cast IN718 aerospace component. Casting simulations are used to compare different thermal conditions around the ceramic shell, with focus on temperature history, heat-flux response, filling and solidification behaviour, shell representation and porosity-related defect indicators. The study treats the ceramic shell as part of the thermal system, rather than only as a geometric boundary, since shell thickness and surrounding boundary conditions affect heat extraction, feeding conditions and last-to-freeze regions. The cast material is not varied as an independent parameter. IN718 is treated as the selected alloy system through which the thermal effects of shell representation and process parameters are interpreted. The simulations show that insulation wrapping has a strong influence on the thermal response of the mould and casting system. Among the investigated process parameters, shell preheat temperature has the strongest influence on the evaluated outputs. Higher shell preheat gives preferable porosity indications, while lower shell preheat gives less favourable indications, especially when combined with lower mass flow. The mass-flow-rate variation has a smaller influence, while the enclosure emissivity has negligible influence for the investigated setup. The comparison between constant and non-uniform shell representations shows that shell representation can affect the local thermal response and predicted defect tendency. However, this effect is smaller than the influence of shell preheat temperature. A limited qualitative comparison with available process observations shows some agreement between simulated defect-indicator regions and observed porosity indications, but the comparison is not sufficient for quantitative validation. The results should therefore be interpreted as simulation-based sensitivity trends that support process understanding, rather than as verified predictions of exact casting quality or as a final production specification.