Sensitivity analysis of several body-in-white single part and assembly parameters using tolerance analysis

Transcription

1 assembly parameters using tolerance analysis Litwa, Frank 1, Gottwald Martin 1, Vicent Gascó 1, Vielhaber Michael 2 1 Daimler AG, Sindelfingen, Germany 2 Institute of Engineering Design Saarland University, Germany Weimar

2 assembly parameters using tolerance analysis - Agenda Overview State of the art interrelationships and dependencies of product and process information State of the art in tolerance analysis Concept to link an optimization tool Abstract concept Workflow in optislang Concept for the Daimler internal Tool TolSim & Optimizer Validation of the concept using a simple example Conclusion and outlook 2 WOST; Frank Litwa; RD/KRR; Daimler AG

3 assembly parameters using tolerance analysis - Agenda Overview State of the art interrelationships and dependencies of product and process information State of the art in tolerance analysis Concept to link an optimization tool Abstract concept Workflow in optislang Concept for the Daimler internal Tool TolSim & Optimizer Validation of the concept using a simple example Conclusion and outlook 3 WOST; Frank Litwa; RD/KRR; Daimler AG

4 assembly parameters using tolerance analysis Overview Motivation: Increasing number of derivatives of one car More intense IT-usage required Need for cutting down the development time of new products Description: Manufacturability of product backed by tolerance simulation More complex products require an experienced tolerance engineer Time consuming build-up process of the tolerance simulation model Optimization of different tolerance concepts based on experts knowledge Scope: The content of this presentation is an approach showing how to interlink optislang to product-/ and production development data and to a CAT-simulation tool to perform sensitivity analysis on the simulations input parameters. Bildquellen: WOST; Frank Litwa; RD/KRR; Daimler AG

5 assembly parameters using tolerance analysis - Agenda Overview State of the art interrelationships and dependencies of product and process information State of the art in tolerance analysis Concept to link an optimization tool Abstract concept Workflow in optislang Concept for the Daimler internal Tool TolSim & Optimizer Validation of the concept using a simple example Conclusion and outlook 5 WOST; Frank Litwa; RD/KRR; Daimler AG

6 assembly parameters using tolerance analysis State of the art 3D CAD data Design (Strak) Assembly graph Gap- and radial plan Jig and fixture concept Requirements Joining elements Datum target points Section cuts Tolerances (GD&T) Measuring points Measurements Results of the Tolerance simulation Tolerance simulation modell Comparison Measurement results 6 WOST; Frank Litwa; RD/KRR; Daimler AG

7 assembly parameters using tolerance analysis State of the art Tolerance chain (definition): A linear dimension chain can be derived from dimensions on parts which are pointing towards the same direction. The closing dimension M0 closes the ends of the linear dimension chain and is specified by a tolerance. This tolerance can be derived out of the dimensional tolerances of the single parts. (Klein 2007) Dimensional technical specifications (definition): A dimensional technical specification is a dimension which is relevant for a specific function in the BiW structure (e.g. connection of the chassis). To ensure manufacturability these dimensions are limited by certain tolerances. 7 WOST; Frank Litwa; RD/KRR; Daimler AG Quelle: F. Litwa

8 assembly parameters using tolerance analysis State of the art Gap- and Radial Plan: In the Gap- and Radial Plan a detailed specification is made describing the dimension of gaps, flushness and radiuses and also the allowed deviation (tolerance) for predefined section cuts of the fully assembled vehicle. RY-577 RX-427 RX-370 The gap- and radial plan is an agreement between the departments of design, product development and production. In an early stage of the product development process this document serves as a default for the product development and later on for the production process. R 0,5 ± 0,1 2 ± 0,5 8 WOST; Frank Litwa; RD/KRR; Daimler AG

9 assembly parameters using tolerance analysis State of the art Initial situation: Deviations of the single parts due to the manufacturing process of the parts Maximum allowed deviation of the parts is limited by the usage of tolerances Deviations of the parts alignment in the jig due to inaccuracies of positioning of the parts Assembling process of the deviating single parts to a higher level assembly leads to a deviation in the closing dimensions Tolerance simulation: For evaluating the range of the deviations during series production tolerance simulation is used. Simulation offers two different types: Tolerance analysis: single part tolerance is known result is the deviation of M 0 Tolerance synthesis: maximum allowed deviation of M 0 is known results is the single parts tolerances 9

10 assembly parameters using tolerance analysis State of the art Basic principle for tolerance simulation Initial Situation ZB Nominal gap in the assembly of an the angle profile and a cuboid Division & Sampling Division of the single parts (ntimes) followed by a random sampling. Angle profile a n Assembling & Measurement Implementetion of the predefined assembling operation followed by a statistical measurement of the gap Removeing All the components are only used once n x angle profile Trash n x cuboid n x Simulation runs cuboid c n ZB n 10 WOST; Frank Litwa; RD/KRR; Daimler AG

11 assembly parameters using tolerance analysis - Agenda Overview State of the art interrelationships and dependencies of product and process information State of the art in tolerance analysis Concept to link an optimization tool Abstract concept Workflow in optislang Concept for the Daimler internal Tool TolSim & Optimizer Validation of the concept using a simple example Conclusion and outlook 11 WOST; Frank Litwa; RD/KRR; Daimler AG

12 assembly parameters using tolerance analysis Concept 3D CAD data Design Assembly graph Gap- and radial plan Jig- and fixture concept Requirements Joining elements Datum target points Section cuts Tolerances (GD&T) Measuring points Optimization Loop Measurements Results of the Tolerance simulation Tolerance simulation modell Comparison Measurement results Input parameters diskrete or continous parameter permitted range is kown Target value continous parameter 12 WOST; Frank Litwa; RD/KRR; Daimler AG

13 Sensitivity Analysis of Several Body-In-White Single Parts and Assembly Parameters Using Tolerance Analysis Concept Product and Process Information Tool for automated CAT-simulation Database Part (Points [FTA, SFK, VE, MP], Tolerances) Assembly Graph Algorithm Creation of 3DCS Model Database (Output) (reduced) *.dcsx-file 3DCS (batch call) Perform TolSim + Results *.csv-file optislang (batch call) *osl3.bin Tool for Variation Analysis Initialization Definition of the working directory Selection of the *.dcsx-file Project Settings Selection of input parameters Selection of output responses Setting of sampling method Determination of number of samples Definition of constraints Creation and Execution of Sensitivity Analysis Visualization of the Results Deviation type Standard deviation Results of Sensitivity Analysis Contributors Meta-Modell 13 WOST; Frank Litwa; RD/KRR; Daimler AG

14 Sensitivity Analysis of Several Body-In-White Single Parts and Assembly Parameters Using Tolerance Analysis Concept Product and Process Information Tool for automated CAT-simulation Database Part (Points [FTA, SFK, VE, MP], Tolerances) Assembly Graph Algorithm Creation of 3DCS Model Database (Output) (reduced) *.dcsx-file 3DCS (batch call) Perform TolSim + Results *.csv-file optislang (batch call) *osl3.bin Tool for Variation Analysis Initialization Definition of the working directory Selection of the *.dcsx-file Project Settings Selection of input parameters Selection of output responses Setting of sampling method Determination of number of samples Definition of constraints Creation and Execution of Sensitivity Analysis Visualization of the Results Deviation type Standard deviation Results of Sensitivity Analysis Contributors Meta-Modell 14 WOST; Frank Litwa; RD/KRR; Daimler AG

15 Sensitivity Analysis of Several Body-In-White Single Parts and Assembly Parameters Using Tolerance Analysis Concept Product and Process Information Tool for automated CAT-simulation Database Part (Points [FTA, SFK, VE, MP], Tolerances) Assembly Graph Algorithm Creation of 3DCS Model Database (Output) (reduced) *.dcsx-file 3DCS (batch call) Perform TolSim + Results *.csv-file optislang (batch call) *osl3.bin Tool for Variation Analysis Initialization Definition of the working directory Selection of the *.dcsx-file Project Settings Selection of input parameters Selection of output responses Setting of sampling method Determination of number of samples Definition of constraints Creation and Execution of Sensitivity Analysis Visualization of the Results Deviation type Standard deviation Results of Sensitivity Analysis Contributors Meta-Modell 15 WOST; Frank Litwa; RD/KRR; Daimler AG

16 Sensitivity Analysis of Several Body-In-White Single Parts and Assembly Parameters Using Tolerance Analysis Concept Product and Process Information Tool for automated CAT-simulation Database Part (Points [FTA, SFK, VE, MP], Tolerances) Assembly Graph Algorithm Creation of 3DCS Model Database (Output) (reduced) *.dcsx-file 3DCS (batch call) Perform TolSim + Results *.csv-file optislang (batch call) *osl3.bin Tool for Variation Analysis Initialization Definition of the working directory Selection of the *.dcsx-file Project Settings Selection of input parameters Selection of output responses Setting of sampling method Determination of number of samples Definition of constraints Creation and Execution of Sensitivity Analysis Visualization of the Results Deviation type Standard deviation Results of Sensitivity Analysis Contributors Meta-Modell 16 WOST; Frank Litwa; RD/KRR; Daimler AG

17 Sensitivity Analysis of Several Body-In-White Single Parts and Assembly Parameters Using Tolerance Analysis Concept Product and Process Information Tool for automated CAT-simulation Database Part (Points [FTA, SFK, VE, MP], Tolerances) Assembly Graph Algorithm Creation of 3DCS Model Database (Output) (reduced) *.dcsx-file 3DCS (batch call) Perform TolSim + Results *.csv-file optislang (batch call) *osl3.bin Tool for Variation Analysis Initialization Definition of the working directory Selection of the *.dcsx-file Project Settings Selection of input parameters Selection of output responses Setting of sampling method Determination of number of samples Definition of constraints Creation and Execution of Sensitivity Analysis Visualization of the Results Deviation type Standard deviation Results of Sensitivity Analysis Contributors Meta-Modell 17 WOST; Frank Litwa; RD/KRR; Daimler AG

18 Sensitivity Analysis of Several Body-In-White Single Parts and Assembly Parameters Using Tolerance Analysis Concept Product and Process Information Tool for automated CAT-simulation Database Part (Points [FTA, SFK, VE, MP], Tolerances) Assembly Graph Algorithm Creation of 3DCS Model Database (Output) (reduced) *.dcsx-file 3DCS (batch call) Perform TolSim + Results *.csv-file optislang (batch call) *osl3.bin Tool for Variation Analysis Initialization Definition of the working directory Selection of the *.dcsx-file Project Settings Selection of input parameters Selection of output responses Setting of sampling method Determination of number of samples Definition of constraints Creation and Execution of Sensitivity Analysis Visualization of the Results Deviation type Standard deviation Results of Sensitivity Analysis Contributors Meta-Modell 18 WOST; Frank Litwa; RD/KRR; Daimler AG

19 Sensitivity Analysis of Several Body-In-White Single Parts and Assembly Parameters Using Tolerance Analysis Concept Product and Process Information Tool for automated CAT-simulation Database Part (Points [FTA, SFK, VE, MP], Tolerances) Assembly Graph Algorithm Creation of 3DCS Model Database (Output) (reduced) *.dcsx-file 3DCS (batch call) Perform TolSim + Results *.csv-file optislang (batch call) *osl3.bin Tool for Variation Analysis Initialization Definition of the working directory Selection of the *.dcsx-file Project Settings Selection of input parameters Selection of output responses Setting of sampling method Determination of number of samples Definition of constraints Creation and Execution of Sensitivity Analysis Visualization of the Results Deviation type Standard deviation Results of Sensitivity Analysis Contributors Meta-Modell 19 WOST; Frank Litwa; RD/KRR; Daimler AG

20 Sensitivity Analysis of Several Body-In-White Single Parts and Assembly Parameters Using Tolerance Analysis Concept Product and Process Information Tool for automated CAT-simulation Database Part (Points [FTA, SFK, VE, MP], Tolerances) Assembly Graph Algorithm Creation of 3DCS Model Database (Output) (reduced) *.dcsx-file 3DCS (batch call) Perform TolSim + Results *.csv-file optislang (batch call) *osl3.bin Tool for Variation Analysis Initialization Definition of the working directory Selection of the *.dcsx-file Project Settings Selection of input parameters Selection of output responses Setting of sampling method Determination of number of samples Definition of constraints Creation and Execution of Sensitivity Analysis Visualization of the Results Deviation type Standard deviation Results of Sensitivity Analysis Contributors Meta-Modell 20 WOST; Frank Litwa; RD/KRR; Daimler AG

21 assembly parameters using tolerance analysis - Agenda Overview State of the art interrelationships and dependencies of product and process information State of the art in tolerance analysis Concept to link an optimization tool Abstract concept Workflow in optislang Concept for the Daimler internal Tool TolSim & Optimizer Validation of the concept using a simple example Conclusion and outlook 21 WOST; Frank Litwa; RD/KRR; Daimler AG

22 D D Sensitivity analysis of several body-in-white single part and assembly parameters using tolerance analysis - Validation 2D-representation for the used example: - Alignment of the two gray parts in the assembly station (3-2-1 alignment) Y6 - Only one tolerance in the assembly station (profile of a surface ±0,5) describing the inaccuracy of the assembling process Y X5 X4 Z2 - Alignment of the blue part at the gray parts as shown - Only one tolerance at the blue part describing the inaccuracy of the stamping process of the single part Z X Z1 Z3 Flushness measurement Three measurements for the resulting gap between the blue part and the dark gray part - Z-alignments of the blue part can be changed in an area of ±4mm 1,0 ZXY Inaccuracy of the fixture Nominal measurement In Y-direction Y Z X 1,0 ZXY Gap measurement 22 WOST; Frank Litwa; RD/KRR; Daimler AG

23 Target values Sensitivity analysis of several body-in-white single part and assembly parameters using tolerance analysis - Validation Results of a sensitivity analysis (CoP-Matrix): + - Input Parameters Z2 Y Z X Z1 Z3 ρ(x,y)= E[(X μ X)(Y μ Y )] σ X σ Y 23 WOST; Frank Litwa; RD/KRR; Daimler AG

24 assembly parameters using tolerance analysis - Validation Results of a sensitivity analysis: - Main contributor for the flushness measurement is the X-direction of the datum target point Z3 + - Z2 Y Z X Z1 Z3 24 WOST; Frank Litwa; RD/KRR; Daimler AG

25 assembly parameters using tolerance analysis - Validation Results of a sensitivity analysis: - Main contributor for the flushness measurement is the X-direction of the datum target point Z3 - Main contributor for the gap measurement is the X-direction of the datum target points Z1 and Z2 Z2 Y Z X Z1 Z3 25 WOST; Frank Litwa; RD/KRR; Daimler AG

26 assembly parameters using tolerance analysis - Validation Results of a sensitivity analysis: - Main contributor for the flushness measurement is the X-direction of the datum target point Z3 - Main contributor for the gap measurement is the X-direction of the datum target points Z1 and Z2 - Main contrubutor for the Y-measurement is the X- direction of the datum target points Z1 and Z2 Y Z2 Z X Z1 Z3 26 WOST; Frank Litwa; RD/KRR; Daimler AG

27 assembly parameters using tolerance analysis - Agenda Overview State of the art interrelationships and dependencies of product and process information State of the art in tolerance analysis Concept to link an optimization tool Abstract concept Workflow in optislang Concept for the Daimler internal Tool TolSim & Optimizer Validation of the concept using a simple example Conclusion and outlook 27 WOST; Frank Litwa; RD/KRR; Daimler AG

28 assembly parameters using tolerance analysis Summary Conclusion & Outlook: Sensitivity analysis of several body-in-white single parts opens up several possibilities: - Main contributions of tolerances in a tolerance chain (similar to HLM analysis in the tolerance simulation) - Statement of how the layout of assembling points (datum target points, jig- and fixture points, welding points) are infecting one (ore more) quality feature(s) More rapid feedback to the designing engineers Study of options available in a very short amount of time Comparison of different alignment concepts, etc. possible Optimization with regards to Robust Design possible Contact: Frank Litwa (Daimler AG) Development Body in White Dimensional Management (RD/KRR) Phone: mailto: Frank.Litwa@daimler.com 28 WOST; Frank Litwa; RD/KRR; Daimler AG