Automation of Plate Handling in Heat Exchanger Assembly: Decision Logic and System Design

Abstract

The interest of implementing automated production has grown over the years
in the industry of manufacturing. Replacing manual tasks with automated
solutions has several advantages, such as improved efficiency, increased
safety and better quality standards. Alfa Laval raised the challenge to find
an automated solution for a currently manual process. The master thesis
addresses the problem with the aim to find a recommended solution. The
solution is supposed to include a design of infeed of plates to assembly of
heat exchangers, as well as handle defective plates and keep the alternating
sequence of two different types of plates.

In collaboration with Alfa Laval, weighted criteria were set to be able
to evaluate and compare different solutions. Through brainstorming and
knowledge gained from the literature study, initial concepts were sketched.
Throughout the process of evaluation, well-known design methodology from
Ulrich and Eppinger was used to determine which concepts to continue
with, redesign or remove from the process. In parallel with development
of concepts, an algorithm had to be developed to handle defective plates
and at the same time keep the alternating sequence of two different types
of plates. Following the first evaluation, the concepts were redesigned and
further developed into more detailed concepts. The three final concepts were
developed further and simulated in Plant Simulation and RobotStudio to
review and analyze. All three concept were able to handle the required
defect rate, arrival rate and rework time. Further evaluation had to be done
to stress test the systems and compare them with the criteria until a final
recommendation was made.

The final concept is based on simple components as powered roller conveyors
and dual chain transfer units and requires only one quality control. It uses
a smart layout to handle disruptions in the sequence without a complicated
algorithm.

Popular Abstract

The process of selecting an automated solution for a manual
manufacturing process can be challenging and complex. This
project explores a structured way of comparing different
solutions by setting up important weighted criteria, using
well known design methodologies, evaluation methods and
simulations.

In the industry of manufacturing, the interest for automation
has grown over the past decades. There are several positive
consequences of implementing an automated production,
including improved efficiency, safety and quality. Automation
has become a major focus for Alfa Laval, leading to replace
manual tasks with automated solutions.

This project finds a general solution for infeed to an automated
assembly process for heat exchangers. More specifically, the
physical design and decision taking related to the infeed to
assembly. The goal is to keep and restore a sequence of
alternating plates in the case of a defective plate. Evaluated
concepts include detailed designs of conveyor infeed systems
with suitable components.

To find the best possible solution, it is important to define goals
and priorities. The priorities were therefore early established
together with Alfa Laval and defined through various criteria.
These criteria were then used throughout the project to
evaluate and compare different designs and solutions.

When the criteria were set, an algorithm was investigated
to solve all possible disruptions in the sequence. The outcome
was a new decision making model for restoring the sequence
of alternating plates. The algorithm was tested and simulated
in ExtendSim. The algorithm is a general decision model
and could potentially be used for the design of other systems in
the future. However, it was not used in the final recommended
solution as it was not required.

The physical layout of the system was then built to support
the decision taking algorithm. This was done in three stages
where the concepts got fewer but increasingly more detailed.
Between each step, evaluation with the design methodology
by Ulrich and Eppinger was used.

After the last evaluation, a final concept of recommendation
was found. The final suggestion include main components,
cost calculation based on quotations, detailed layout and
confirmation of an operational concept from simulations in
RobotStudio and Plant Simulation.

Concept D was selected as the recommended solution,
a description is presented below. The final concept is a
smart solution that is supported by straightforward logic to
handle flow of plates, requires no complex decision-making
algorithm, only one quality control and provides an
implementation of a simple system.

The design evaluation methodology by Ulrich and Eppinger
gave the project a structured and well organized way of
developing concepts. The methodology can handle both
quantitative and subjective results and assumptions, which
was very useful due to the wide range of criteria found in
this project. The approach inspired Alfa Laval to integrate the
process of evaluation in upcoming projects.

The next step of the process is to develop both a quality
control system and a plate recognition system for A and B
plates. The implementation of these systems were not part
of the thesis. In the last stages, the ability of the concept to
handle changes in requirements was evaluated. Alfa Laval
expressed that the focus of improvement for the future would
to decrease the defect rate. The recommended solution would
handle the decrease of defect rate, with no need for changes
in layout

• author: Källåker, Erik and Andersson, Stina
• supervisor: Erik Ottosson
• organization: Division for Industrial Electrical Engineering and Automation
• course: EIEM01 20252
• year: 2026
• type: H3 - Professional qualifications (4 Years - )
• subject: Technology and Engineering
• keywords: Heat exchanger, Automation, Decision-making, Algorithm, Design methodology, Quality control, Defect products, System design, Decision logic, Production, Material sorting, Conveyor, Robot, RobotStudio, Plant Simulation, Simulation
• publication/series: CODEN:LUTEDX/TEIE
• report number: 5557
• language: English
• id: 9218638
• date added to LUP: 2026-01-20 10:29:33
• date last changed: 2026-01-20 10:29:33