The engineering service requested by Sedat Üstündağ construction company for the 40 m tall Atatürk Statue to be built in Buca district of Izmir made our company proud in this regard, and we had the chance to contribute to the Mask (sculpture) of Atatürk, the founder of the Republic of Turkey, to be built in this size. The work to be done was to provide a large-scale engineering structure of a model created by the sculptor.

PROJECT START

The concept determined for the 40 m high Ataturk Mask was chosen as the Ataturk portrait worth over 20 YTL. The sculpture work, created from a clay model made by sculptor Harun Atalayman, was appreciated by the Buca municipal authorities, the owner of the project, and it was decided to continue the project with this work as the basis.

Project; The model, which was finalized by Harun Atalayman, was delivered to Defne Engineering for the purpose of making a copy of the epoxy mold for measurement and engineering studies and transferring this copy to the computer environment by optical scanning method.

Picture 1: Preparation of the mud model by sculptor Harun Atalayman

Picture 2: Model prepared for 3D dimensioning

Defne Engineering started the engineering work of this project with the help of both 3D measurement and the evaluation of the obtained data in accordance with the project purpose and its experiences in mold production, quality control and product development.

The engineering works to be completed in 4 main stages are defined as follows:

Stage 1: Transferring the step-by-step model to the computer environment:

The first stage of the plan, which consists of 4 main stages, is the creation of computerized forms of the model. With the experience gained from both automotive and other main industry branches, Defne Engineering transferred the sample taken from the hand-made model to the computer environment with the help of sample fixturing and Breuckmann opto-TOP HE system. The model prepared for measurement was 1 meter in size, and the appropriate camera and field of view were selected, and 3D measurement was made in a way that could capture all the geometric details of the prepared model, but eliminate small errors caused by hand production. As a result of this measurement, the scanning data, which we call point cloud, was prepared in STL format. These data; It will form the basis for other stages such as scaling, form creation, and determination of structural elements from the formed forms.

Picture 3 : STL data

Stage 2: The data required for both capturing the form and structural analysis are collected.

The measurements obtained as a result of optical scanning were enlarged for 4 m and 40 m models. Sections were created on the CAD data in radial and polar axes. These sections and joints were used both to define the form for the sculpture to be made by creating a network structure and to design the outline of the carcass structure to be used inside. Technical drawings and all necessary measurements of these sections were prepared and taken as reference data for the sculpture(s) to be made. When the production started in the basic dimensions of the building, where only the mask length was planned to be 40 meters, cross-sectional profiles were prepared at 1 meter intervals in order not to deviate from the accepted design and to make it exactly similar to the Atatürk model. These sections were taken as gauges and the profiles used in the main structures were produced according to these gauges.

Picture 4: Network structure created on CAD data

The resulting network structure has been prepared to be used both in defining the form on a large scale and in the static analysis of the carcass structure to be used in it. Dear Prof. Dr. By Hikmet Aydin; The material, profile type, thickness, and carrier system design to be used in the sculpture, whose structural tests were carried out, were calculated using this network structure.

Stage 3: Determining the location of the new model with the hill data and creating the hill layout plan.

During the creation of the mud model, measurements were taken regarding the location where the statue would be placed. These measurements were data taken with a laser pointer from the slope from the base of the statue to the top. These data from the ground where the pedestal will sit and between the peaks are combined with the data obtained from the mud model. The most suitable place on the base floor has been determined.

According to these data, the portrait part that will form the main figure was positioned to scale, taking into account the base at the bottom and the total height.

The 4th stage is the integration of natural rock views and the surroundings of the sculpture in harmony with the environment.

The distance between the statue and the hill behind it must be completed both statically and visually and integrated with the environment in which it is located. For this purpose, natural rocks were added to the existing model by making another sculptural work to fill the gaps. This model was also dimensioned and transferred to the computer environment. With this preliminary study, it was tried to foresee how natural rocks can be used in the space and what construction needs to be done to associate them with the hill.

Picture 5: Natural Rock addition work

This mask, whose construction was completed in Çaldıran District of İzmir Buca Municipality, arouses the admiration of those who see it with its great magnificence. In order to understand the size of the work from the photographs, you can see people with an average height of 1.75m standing next to the Ataturk Mask in picture no. 15. In this form, the work has been applied to be registered in the Guinness World Records as the largest mask.

As Defne Engineering, we are proud to be able to contribute to this study. This statue, built in memory of the great leader Atatürk, will continue to be a source of pride for both your company and our country.
regards

The post Izmir Ataturk Statue first appeared on Defne Mühendislik Ürün Tasarım, Geliştirme & Geriye Dönük Mühendislik Hizmetleri.

Our urban bus development project with a new concept, which we started with our customer in 2008, has started mass production. The vehicles produced have become more popular than their competitors in the Middle East and Asian markets, especially in Azerbaijan.

Concept, detail and production designs of the front and rear of the vehicle are by Defne Mühendislik Ltd. Ltd. It is another source of pride for us that the vehicle produced by Ashok Leyland was appreciated and put into mass production by an international company with experience in R&D and design, operating in 30 countries. India’s gross domestic product ranks fourth in the world. It is predicted that it will be among the top three countries in 2020. Ashok Leyland, one of the companies that can analyze the Asian and European markets well, says that the domestic designs made in our country; It is one of the companies that can predict that they will find a high market share in the countries where they operate.

The new concept design using Reverse Engineering tools was obtained as a result of our company’s dedicated and intense work on Industrial Product Development, detail design, manufacturability and quality in details. The main carcass structure to be used in the production of the vehicle was transferred to the computer environment with the 3D measurement method, and the concept was developed in accordance with this structure. In vehicle design, 2nd degree continuous surfaces called A-Class were created with the advanced surface modeling method. Mechanical and production details studies were carried out by choosing one of the 3 different alternatives created.

The vehicles exhibited in Busworld 2012 Istanbul, produced in two different lengths of 5.5m and 7.5m, are released to the market as alternative series for different purposes with different interior equipment. The development of products for the domestic sales of the vehicles, which received very positive reactions from the domestic market in terms of body appearance at the Busworld 2012 fair, continues.

Valuation of domestic designs in international markets in our country, where the infrastructure of domestic vehicle production has been established, will form the stepping stones on our country’s path to becoming a design base from contract manufacturing with this and similar projects.

Seeing the traces of domestic designs in foreign markets and contributing to our country’s progress in design and production is a hopeful step for both our company and the domestic industry. Such developments for export are much more valuable than the share gained in the local market. The orientation of production and R&D structuring towards exports is the most important factor that will make our country stand out in the global economy.
regards

The post Our Designs are in International Markets first appeared on Defne Mühendislik Ürün Tasarım, Geliştirme & Geriye Dönük Mühendislik Hizmetleri.

Defne Engineering company has extensive experience in the design and development of mechanical superstructures of electronic products. Its experience in cash registers and payment recording devices, which it had previously developed and used in the market, has been strengthened.

This product, whose concept and mechanical design was carried out by Defne Engineering with our Industrial Product design, Value Engineering studies, has achieved pioneering and leadership in payment recording devices. It was launched as a first in its class.

As a result of the innovation and creativity work carried out with our customers in design and development, the product was released to the market faster, higher quality and more reliable than its competitors. This high quality was achieved thanks to the engineering studies carried out in the design and production stages.

At the product concept stage, ease of service, customer needs, usage environment and modularity were taken as basis. We developed the concept design phase with our customer. A team of different disciplines worked to ensure that the resulting concept kept up with the advancing technology and to ensure that both the mechanical and electronic infrastructure were up-to-date.

The product family, whose design phase was completed, was pre-manufactured using special and classical manufacturing methods for testing and validation studies.

With its electronic and mechanical infrastructure based on the latest advanced technology, it has successfully passed all tests and has been approved.

A first in its sector, the product family has gained sustainable leadership in terms of its quality, safety, reliability, service and durability.

The post New Generation Cash Register first appeared on Defne Mühendislik Ürün Tasarım, Geliştirme & Geriye Dönük Mühendislik Hizmetleri.

Defne Engineering Ltd. Ltd. We have been carrying out product design and product development studies since 2005. We have successfully completed more than 7000 product design, product development, backward engineering and benchmark projects for different sectors, especially the defense, aerospace, automotive, white goods and medical sectors.

To carry out new projects in different sectors in areas where we have not worked before; It helps us both create a success story and increase our professional satisfaction. These types of studies; It is a serious source of motivation for us as it adds value to our company’s creativity development and projects.

Another advantage of carrying out different projects from many different sectors is that the creative ideas to be used in new development projects are based on experience.

As Defne Engineering, cover design, development, optimization, testing and prototype production work was carried out for Li-Ion rechargeable batteries that will be used in satellite systems in 2020. These design and development studies for Li-Ion rechargeable batteries with prismatic geometry make energy storage safer and more controllable both in space studies and in different sectors such as electrically powered transportation vehicles, electronics, medical and defense where rechargeable batteries are used.

Since the main criteria of the product design project are environmental conditions in the space environment, there are standards that must be followed in the materials to be used and the products produced from these materials, especially in the manufacturing and assembly processes. These standards are defined by the European Cooperation for Space Standardization (ECSS) and the National Aeronautics and Space Administration (NASA). In addition to these operating conditions, it is a must for the rechargeable battery to be resistant to the additional pressure, temperature, chemical substances and electrical environment that may occur during the functioning of the product, together with its sub-parts. All criteria, from the materials to be selected to the production method and the final product, must meet the main standards and their sub-conditions defined by these two institutions.

It consists of the main plate on the battery cover, anode and cathode pole, mechanical current interrupter system (CID), valve defined as emergency safety valve and sealing elements. The main headings and stages of the work carried out for the cover and lower parts are as follows:

In product design studies, a detailed project plan was created at the beginning of the project. The current plan was updated in the later stages of the project and revisions were made to its details. By adhering to the master plan, the project was delivered on time and with the highest quality.

Figure 2: CID mechanism research

It is necessary to use scientific studies and new approaches in the product design studies where the working environment is space, such as satellite systems, where high technology products are used, and to be verified by physical tests. International scientific articles were searched for previous mechanical designs on the product and its sub-parts, as well as the mechanical properties and production methods of these parts. Both the mechanical systems in which the products perform their functions and the development of the production processes of these products guide scientific studies and articles today. Articles and patents published, especially in China, show that developments on this subject are still ongoing. Patent research, which is the first stage of the design study; Examination, classification and interpretation of both international patents and scientific articles published on this subject were carried out.

Concepts have been created for the mechanical current interrupter (CID) mechanism, valve and terminals in accordance with the battery sizes to be used. Designs were shaped to include mechanical details for a few models selected from these concepts created during the conceptual design phase. At this stage, production methods are formed along with their alternatives.

All materials to be used in the battery cover must be approved to the standards and environmental conditions defined by NASA. In addition, in order for the materials of some sub-parts to fulfill their mechanical duties, their behavior in the non-linear region in the stress and elongation graph is taken as basis. The material must fulfill its function in this behavior zone but must also be far from the rupture limit. This type of material shows the same mechanical properties within certain tolerances in every production package. In order to ensure that the mechanical properties of the materials to be used in our project are not affected by differences in production packages, materials produced at once were supplied and used in testing and production. Some materials were brought closer to the desired mechanical behavior profile by additionally applying special heat treatments. The same materials were subjected to tensile tests in Kosgeb and the manufacturing companies and stress-strain curve profiles were obtained. These profiles were used in non-linear structural simulation studies to obtain results closest to reality. According to these results, the material geometric properties were optimized to meet the operating conditions.

Figure 3: Bulk tensile test results

In addition to subjecting each component to a computer simulation in the working environment to fulfill its function individually, structural optimizations were carried out on the entire system by examining the integrated product’s response to environmental tests with non-linear analysis. By taking this optimization material properties, production and production processes into consideration, a geometric and mechanical design suitable for mass production has been developed. Thus, the problems that are very difficult to supply or that may occur during the production process due to dimensional tolerance deviations from production have been minimized with the optimization work at this stage.

In the optimization study, details of the production processes were tried to be prevented, such as tolerance accumulation that may occur in the sub-parts during production. The waste rate in production has been tried to be minimized with test productions and apparatus-fixture designs made during the production phase. With production process optimization, waste rates in the production of sub-parts have been improved by up to 70%.

Figure 4: Subsystem analysis with nonlinear analysis

Each part was produced in multiple quantities, taking into account repeatability on mass production machines and conditions, and was first subjected to simple workshop tests and then to environmental tests in an independent testing institution to meet ECSS standards. Sixty percent success rate was achieved in the first tests. Thanks to the improvement of production processes and environments, a 90% success rate of approval was obtained in part-based tests.

Polyphenylene Sulfide (PPS) material was chosen as the sealing element due to its electrical resistance, chemical resistance and mechanical properties. A scientific study was also carried out during this project with the plastic injection method using γ-aminopropyltriethoxy silane-based binder to ensure that PPS remains sealed with aluminum at high pressure and temperature. A side benefit of this study is that the PPS product obtained by domestic production, if used with the developed process, achieved the desired success in ECSS tests.

Figure 5: Schematic representation of the PPS – Aluminum chemical connection

The lithum cell and its box, called jelly roll, together with the battery cover, constitute a unit battery. This product has been subjected to simulation tests with FRF (Frequency Response Analysis PSD (Random Vibration Analysis) SRS (Shock Response Spectrum Analysis) finite element analysis in ECSS-E HB-32-26A standards. The assembled version of the entire system is far from critical values, Real Reporting was created on the basis that the tests should be easily passed.

Figure 6: FRF and SRS results of Li-Ion whole battery

With the experience gained from these tests, the designs and processes of the entire product’s apparatus, fixtures and molds were reviewed, improved, developed and produced. There are 11 sub-parts and more than 33 processes in the battery cover part. Following the successful completion of the physical environment tests of the sub-components of the cover product, assembled production was carried out. Assembled production is subjected to tests at ECSS starts and development processes continue.

Figure 7: Prototype pre-series production

The development and improvement efforts of the battery cover, whose pre-mass production has been successfully completed, continue. The achievements of this successfully completed project, albeit in a different sector, will enable us to achieve much more creative and quality results in our new works. Continuing its work with a center of excellence approach, our company will continue to serve with its developing staff to provide new gains to our country.

The post Battery Cover Design and Production first appeared on Defne Mühendislik Ürün Tasarım, Geliştirme & Geriye Dönük Mühendislik Hizmetleri.

Engineering and design work has been carried out on the domestically designed and produced passenger aircraft project for TSI AVIATION SEATS, a Kibar Holding partnership, since 2012.

Our company contributed to the design and engineering of this process, which lasted more than 2 years, in the creation of benchmarks within the framework of the project, the realization of mechanical and mechanism design based on the concept design, manufacturing developments and prototype production.

We are proud of our contribution to the realization of the domestic design and production project in the Turkish aviation industry.

The fact that our country has high-tech products supported by innovative ideas in global markets is proof that serious projects can be realized when given the opportunity.

The post Airplane Seat Design first appeared on Defne Mühendislik Ürün Tasarım, Geliştirme & Geriye Dönük Mühendislik Hizmetleri.

Defne Muhendislik  provides services only  on project basis to all the sectors who are into product development and/or  improvement. Although they are able to do their own design , prototype or reverse engineering  tasks, firms  need  this kind of supports because of project schedule  and workload .They can get  this kind of support only from  a company  which  is the expert  in  its  field.

Defne Muhendislik  is expanding  the works about 3-dimensional scanning , reverse engineering , product design with its experienced engineer  by using 2 Breuckmann Opto-Top HE system, Rapidform, CATIA and Top Solid  software.  Differently from other works Defne Muhendislik, benefited from  the  gained experiences , carried out precision works in archaeology area.

Considering delicate and brittle nature of the historical artifacts  reproducing or getting a   replica is not possible for every  artifact. The Classical  method of getting a silicon mold  can damage the artifacts  and  prevents obtaining the desired  precision and details because of the unavoidable  air bubbles  and chemicals reactions. We  were able to  achieve  perfect results  without  touching the artifact  by using  a Breuckmann  System. Our gained experience and equipment was  enabled us  to carry out the measurements  for  the replica of the SILOAM inscription.

Siloam  inscription  was measured  with  Breuckman Opto_Top HE  optic  System. Acquired   point cloud  prepared  as polygon  data and  processed  for machinability to run with CNC. Appropriate  lens configuration and system  software parameters  settings  are made  for sticking to authentic SILOAM  inscription and transferring  the  time-related abrasion and the natural texture  on the artifact  into the  computer setting. Measurements, transferred into the computer, had to be processed  without  converting to any other format.  Post processing was done  only  by sticking to the raw data because conversion  of data  and the surface  formation  would lead  to the details to be lost. After this stage CAM data was  prepared  from the point cloud to generate tool  path .

During the CNC  operations,  high-speed  cutting is performed with as small as possible  diameter  tools  in order to bring out the details of the artifact  on to the  material of the model. After 144 hours  CNC operations ,  processed model   was  containing  not only the natural  information  but also all the details of the SLOAM inscription.

After the  process of transferring the inscription on to the model , colour and pattern  works are done by sticking to original artifact . In this  pattern work  super thin and strong paint is used so that  paint does not cover all the details  but at the same time it can provide necessary  colour .

As a result of working with the excitement of measuring 2700  yers old  historical artifact and the pride of adding positive value to the history, we achieved high customer satisfaction.

This artifact  which belongs to our country will not  be exposed to the risks anymore such as travelling long distances for  exhibitions.

About the inscription 

The post The Siloam Inscription first appeared on Defne Mühendislik Ürün Tasarım, Geliştirme & Geriye Dönük Mühendislik Hizmetleri.