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Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis
Litwa, Frank1, Gottwald Martin1, Vicent Gascó1, Vielhaber Michael2
1 Daimler AG, Sindelfingen, Germany2 Institute of Engineering Design Saarland University, Germany
Weimar 04.-06.11.2015
Sensitivity analysis of several body-in-white single part and
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
WOST; Frank Litwa; RD/KRR; Daimler AG 2
Sensitivity analysis of several body-in-white single part and
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
Sensitivity analysis of several body-in-white single part and
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
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.
4
Time consuming build-up process
of the tolerance simulation model
Optimization of different tolerance
concepts based on experts knowledge
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WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity analysis of several body-in-white single part and
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
Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis – State of the art
6
Tolerance simulation modell
Results of the
Tolerance simulationComparison
Design (Strak)
Gap- and radial plan
Section cuts
Measurements
Requirements
Measurement results
3D CAD data
Jig and fixture concept
Measuring points
Joining elements Datum target points
Tolerances (GD&T)
Assembly graph
WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity analysis of several body-in-white single part and
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
Quelle: F. Litwa
WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity analysis of several body-in-white single part and
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.
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.
8 WOST; Frank Litwa; RD/KRR; Daimler AG
2 ± 0,5
R 0,5 ± 0,1
RY-577RX-427 RX-370
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.
9
Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis – State of the art
Simulation offers two different types:
Tolerance analysis: single part tolerance is known result is the deviation of M0
Tolerance synthesis: maximum allowed deviation of M0 is known results is the
single parts tolerances
10
B
asi
c p
rin
cip
lefo
rto
lera
nce
sim
ula
tion Initial Situation ZB
Nominal gap in the assembly of an the
angle profile and a cuboid
ZBn
Assembling & Measurement
Implementetion of the predefined
assembling operation followed by a
statistical measurement of the gap
Division & SamplingDivision of the single parts (n-
times) followed by a random
sampling.
n x Simulation runs
RemoveingAll the components are
only used once Trash
Angle profile an cuboid cn
n x angle profile n x cuboid
WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis – State of the art
Sensitivity analysis of several body-in-white single part and
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
Design
Datum target points
Gap- and radial plan
Section cuts
Measurements
Requirements
Measurement results
3D CAD data
Jig- and fixture concept
Joining elements
Tolerances (GD&T) Measuring points
Assembly graph
Target value
Loop
Input parameters
• diskrete or
continous
parameter
• permitted
range is kown
• continous
parameter
Optimization
WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis – Concept
Tolerance simulation modell
Results of the
Tolerance simulationComparison
13 WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity Analysis of Several Body-In-White Single Parts and
Assembly Parameters Using Tolerance Analysis – Concept
Tool for Variation Analysis
Initialization
• Definition of the working directory• Selection of the *.dcsx-file
• Selection of input parameters• Selection of output responses• Setting of sampling method• Determination of number of samples• Definition of constraints
Project Settings
Visualization of the Results
Results of TolSim
• Deviation type• Standard deviation• …
Results of Sensitivity Analysis
• Contributors• Meta-Modell• …
Perform TolSim + Results
3DCS (batch call)
*.csv-File
optiSLang (batch call)
*osl3.bin
Database
• Part (Points [FTA, SFK, VE, MP], Tolerances)
• Assembly Graph
*.dcsx-file
Database (Output) (reduced)
Algorithm
• Creation of 3DCS Model
Results of TolSim
Creation and Execution
of Sensitivity Analysis
Product and Process Information
Tool for automated CAT-simulation
14 WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity Analysis of Several Body-In-White Single Parts and
Assembly Parameters Using Tolerance Analysis – Concept
Tool for Variation Analysis
Initialization
• Definition of the working directory• Selection of the *.dcsx-file
• Selection of input parameters• Selection of output responses• Setting of sampling method• Determination of number of samples• Definition of constraints
Project Settings
Visualization of the Results
Results of TolSim
• Deviation type• Standard deviation• …
Results of Sensitivity Analysis
• Contributors• Meta-Modell• …
Perform TolSim + Results
3DCS (batch call)
*.csv-File
optiSLang (batch call)
*osl3.bin
Tool for automated CAT-simulation
Database
• Part (Points [FTA, SFK, VE, MP], Tolerances)
• Assembly Graph
*.dcsx-file
Database (Output) (reduced)
Algorithm
• Creation of 3DCS Model
Results of TolSim
Creation and Execution
of Sensitivity Analysis
Product and Process Information
15 WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity Analysis of Several Body-In-White Single Parts and
Assembly Parameters Using Tolerance Analysis – Concept
Tool for Variation Analysis
Initialization
• Definition of the working directory• Selection of the *.dcsx-file
• Selection of input parameters• Selection of output responses• Setting of sampling method• Determination of number of samples• Definition of constraints
Project Settings
Visualization of the Results
Results of TolSim
• Deviation type• Standard deviation• …
Results of Sensitivity Analysis
• Contributors• Meta-Modell• …
Perform TolSim + Results
3DCS (batch call)
*.csv-File
optiSLang (batch call)
*osl3.bin
Tool for automated CAT-simulation
Database
• Part (Points [FTA, SFK, VE, MP], Tolerances)
• Assembly Graph
*.dcsx-file
Database (Output) (reduced)
Algorithm
• Creation of 3DCS Model
Results of TolSim
Creation and Execution
of Sensitivity Analysis
Product and Process Information
16 WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity Analysis of Several Body-In-White Single Parts and
Assembly Parameters Using Tolerance Analysis – Concept
Tool for Variation Analysis
Initialization
• Definition of the working directory• Selection of the *.dcsx-file
• Selection of input parameters• Selection of output responses• Setting of sampling method• Determination of number of samples• Definition of constraints
Project Settings
Visualization of the Results
Results of TolSim
• Deviation type• Standard deviation• …
Results of Sensitivity Analysis
• Contributors• Meta-Modell• …
Perform TolSim + Results
3DCS (batch call)
*.csv-File
optiSLang (batch call)
*osl3.bin
Tool for automated CAT-simulation
Database
• Part (Points [FTA, SFK, VE, MP], Tolerances)
• Assembly Graph
*.dcsx-file
Database (Output) (reduced)
Algorithm
• Creation of 3DCS Model
Results of TolSim
Creation and Execution
of Sensitivity Analysis
Product and Process Information
17 WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity Analysis of Several Body-In-White Single Parts and
Assembly Parameters Using Tolerance Analysis – Concept
Tool for Variation Analysis
Initialization
• Definition of the working directory• Selection of the *.dcsx-file
• Selection of input parameters• Selection of output responses• Setting of sampling method• Determination of number of samples• Definition of constraints
Project Settings
Visualization of the Results
Results of TolSim
• Deviation type• Standard deviation• …
Results of Sensitivity Analysis
• Contributors• Meta-Modell• …
Perform TolSim + Results
3DCS (batch call)
*.csv-File
optiSLang (batch call)
*osl3.bin
Tool for automated CAT-simulation
Database
• Part (Points [FTA, SFK, VE, MP], Tolerances)
• Assembly Graph
*.dcsx-file
Database (Output) (reduced)
Algorithm
• Creation of 3DCS Model
Results of TolSim
Creation and Execution
of Sensitivity Analysis
Product and Process Information
Product and Process Information
18 WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity Analysis of Several Body-In-White Single Parts and
Assembly Parameters Using Tolerance Analysis – Concept
Tool for Variation Analysis
Initialization
• Definition of the working directory• Selection of the *.dcsx-file
• Selection of input parameters• Selection of output responses• Setting of sampling method• Determination of number of samples• Definition of constraints
Project Settings
Visualization of the Results
Results of TolSim
• Deviation type• Standard deviation• …
Results of Sensitivity Analysis
• Contributors• Meta-Modell• …
Perform TolSim + Results
3DCS (batch call)
*.csv-File
optiSLang (batch call)
*osl3.bin
Tool for automated CAT-simulation
Database
• Part (Points [FTA, SFK, VE, MP], Tolerances)
• Assembly Graph
*.dcsx-file
Database (Output) (reduced)
Algorithm
• Creation of 3DCS Model
Results of TolSim
Creation and Execution
of Sensitivity Analysis
19 WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity Analysis of Several Body-In-White Single Parts and
Assembly Parameters Using Tolerance Analysis – Concept
Tool for Variation Analysis
Initialization
• Definition of the working directory• Selection of the *.dcsx-file
• Selection of input parameters• Selection of output responses• Setting of sampling method• Determination of number of samples• Definition of constraints
Project Settings
Visualization of the Results
Results of TolSim
• Deviation type• Standard deviation• …
Results of Sensitivity Analysis
• Contributors• Meta-Modell• …
Perform TolSim + Results
3DCS (batch call)
*.csv-File
optiSLang (batch call)
*osl3.bin
Tool for automated CAT-simulation
Database
• Part (Points [FTA, SFK, VE, MP], Tolerances)
• Assembly Graph
*.dcsx-file
Database (Output) (reduced)
Algorithm
• Creation of 3DCS Model
Results of TolSim
Creation and Execution
of Sensitivity Analysis
Product and Process Information
20 WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity Analysis of Several Body-In-White Single Parts and
Assembly Parameters Using Tolerance Analysis – Concept
Tool for Variation Analysis
Initialization
• Definition of the working directory• Selection of the *.dcsx-file
• Selection of input parameters• Selection of output responses• Setting of sampling method• Determination of number of samples• Definition of constraints
Project Settings
Visualization of the Results
Results of TolSim
• Deviation type• Standard deviation• …
Results of Sensitivity Analysis
• Contributors• Meta-Modell• …
Perform TolSim + Results
3DCS (batch call)
*.csv-File
optiSLang (batch call)
*osl3.bin
Tool for automated CAT-simulation
Database
• Part (Points [FTA, SFK, VE, MP], Tolerances)
• Assembly Graph
*.dcsx-file
Database (Output) (reduced)
Algorithm
• Creation of 3DCS Model
Results of TolSim
Creation and Execution
of Sensitivity Analysis
Product and Process Information
Sensitivity analysis of several body-in-white single part and
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
Y
XZ
+
-
Flushness measurement
Gap measurement
Nominal measurement
In Y-direction
Inaccuracy of the fixture
22
2D-representation for the used example:
WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis - Validation
X4
X5
Y
XZ
- Alignment of the two gray parts in the assembly station
(3-2-1 alignment)
- Only one tolerance in the assembly station (profile of a
surface ±0,5) describing the inaccuracy of the
assembling process
- 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
- 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
1,0D ZXY
1,0D ZXY
Z3Z1
Z2
Y6
23
Results of a sensitivity analysis (CoP-Matrix):
WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis - Validation
Y
XZ
+
-
Z3Z1
Z2
Input Parameters
Targ
et
va
lue
s
𝜌(X,Y)=𝐸[(𝑋 − 𝜇𝑋)(𝑌 − 𝜇𝑌)]
𝜎𝑋𝜎𝑌
24
Results of a sensitivity analysis:
WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis - Validation
- Main contributor for the flushness measurement
is the X-direction of the datum target point Z3
Y
XZ
+
-
Z3Z1
Z2
25
Results of a sensitivity analysis:
WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis - Validation
- 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
Y
XZZ1
Z2
Z3
26
Results of a sensitivity analysis:
WOST; Frank Litwa; RD/KRR; Daimler AG
Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis - Validation
- 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
XZZ3Z1
Z2
Sensitivity analysis of several body-in-white single part and
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 WOST; Frank Litwa; RD/KRR; Daimler AG
• 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
Sensitivity analysis of several body-in-white single part and
assembly parameters using tolerance analysis – Summary
Frank Litwa (Daimler AG)
Development Body in White
Dimensional Management (RD/KRR)
Phone: + 49 7031 9078210
mailto: [email protected]
Conclusion & Outlook:
Contact: