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CATIA Integrated Tolerance Analysis - 3DCS for CATIA V5

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3DCS Variation Analyst CAA V5 Based Software is used by manufacturers across the globe for Tolerance Analysis to reduce scrap, rework and warranty claims.

3DCS Variation Analyst CAA V5 Based (3DCS for V5) is an integrated software solution in CATIA V5 that simulates product assembly and part tolerance 3D stack-ups through Monte Carlo Analysis and High-Low-Mean (Sensitivity) Analysis.

Model Part and Process Variation - How does it work?

Use CATIA FTA - Embedded GD&T3DCS for V5 uses three methods of simulation; Monte Carlo Simulation, High-Low-Mean (Sensitivity analysis) and GeoFactor Analysis. These together highlight the sources of variation as well as potential build issues in the product.

By accurately modeling the build process, users can determine how their process will affect the assembly in addition to their part tolerance stack-up. This together essentially creates a virtual prototype that can be used to make decisions about design changes and tooling while reducing scrap and rework.

Learn more at: http://www.3dcs.com/tolerance-analysis-software-and-spc-systems/3dcs-software/catia-v5-integrated

Publié dans : Ingénierie
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CATIA Integrated Tolerance Analysis - 3DCS for CATIA V5

  1. 1. Dimensional Control Systems | 2017 All Rights Reserved 3DCS Variation Analyst for CATIA Tolerance Analysis Software fully integrated into Dassault Systemes CATIA CAD Platform
  2. 2. Dimensional Control Systems | 2017 All Rights Reserved 3DCS Fully Integrated in CATIA • 3DCS Model is stored in CATProducts • Utilize any PLM system that stores your CATIA Model • Support for CATIA V5-6, R19-26, including R2014,2015,2016 • Point and Feature Based modeling • Use Enhanced Scenes to create scenarios • No loss of data through translation. • Measurement Point Coordination between CAD and 3DCS • Extract and use CATIA GD&T (FTA) and Joints and Constraints
  3. 3. Dimensional Control Systems | 2017 All Rights Reserved What is 3DCS Variation Analyst? CAD based tolerance and process analysis software Integrated Into: Dassault Systemes CATIA V5-6 CATIA 3DEXPERIENCE Siemens NX PTC Creo Available also in a CAD neutral stand alone version
  4. 4. Dimensional Control Systems | 2017 All Rights Reserved What is a Variation Analyst Model? A CAD model that incorporates part tolerances, assembly process and inspection measurements inside 3DCS software
  5. 5. Dimensional Control Systems | 2017 All Rights Reserved Why Use 3DCS? Determine how part and assembly tolerances affect the overall build and fit of a product. Will my current design work? How well? Where should I measure in production? Where will I have manufacturing problems specifically? How will tooling affect my product? Can I change the assembly process to reduce variation? How do I fix variation issues? Get Answers:
  6. 6. Dimensional Control Systems | 2017 All Rights Reserved 3DCS Inputs Part Geometry – GD&T and Tolerances Assembly Sequence – Moves to assemble the parts Measurements – Areas to analyze during simulation
  7. 7. Dimensional Control Systems | 2017 All Rights Reserved 3DCS Outputs High-Low-Mean Sensitivity Analysis – How much does the tolerance range affect the product GeoFactor Results – How much does the part geometry contribute to the product’s variation Monte Carlo Simulation - • Quality Metrics – Pp, Cp, Ppk, Cpk – Methods of measuring variation in production • Key Contributors – Where is the variation coming from • Percent Out-of-Spec – How many builds will fail to meet Specifications (non- conformance) • Range of Variation – How much variation will be in the product (worst case)
  8. 8. Dimensional Control Systems | 2017 All Rights Reserved 3DCS as Part of PLM Design Simulation ValidationRedesign Manufacturing Gap and Flush Objectives Tooling Design Optimize Tolerances GD&T and Assembly Sequence Inspection Plan and Measurement AuthoringTest Solutions to Control Variation Use Plant Data to Root Cause Issues 3DCS can be used throughout the product lifecycle to support Dimensional Quality and PLM Spec Study and Visualization Monte Carlo Simulation Sensitivity AnalysisWhat If Studies Process Capability DB
  9. 9. Dimensional Control Systems | 2017 All Rights Reserved 3DCS in a Closed Loop System Quality Intelligence Engineering Through Production
  10. 10. Dimensional Control Systems | 2017 All Rights Reserved 3DCS FUNCTIONALITY How does it work
  11. 11. Dimensional Control Systems | 2017 All Rights Reserved Monte Carlo Analysis Determine if the results of a measurement (specific area) will meet design objectives based on a randomly varied tolerances across a series of simulated product builds. The statistical output of the simulation is displayed as a histogram showing the frequency that the measurement is out of specifications • Mean • Standard Deviation • Distribution • Selectable Metrics (Pp, Cp, Ppk, Cpk etc…)
  12. 12. Dimensional Control Systems | 2017 All Rights Reserved HLM Sensitivity A "High-Low-Median", or HLM, Sensitivity Analysis provides information to make improvements to the model. HLM Sensitivity determines which tolerances have the largest contribution per measurement.
  13. 13. Dimensional Control Systems | 2017 All Rights Reserved GeoFactor Similar to the High-Low-Median sensitivity analysis, GeoFactor examines the effect of each tolerance on a given measurement. Unlike HLM sensitivity, which analyzes the range of a tolerance, GeoFactor analysis examines the contribution of the tolerance based on geometry effect.
  14. 14. Dimensional Control Systems | 2017 All Rights Reserved USING 3DCS VARIATION ANALYST Using 3DCS
  15. 15. Dimensional Control Systems | 2017 All Rights Reserved Model Inputs Part Geometry – • GD&T and Tolerances Assembly Sequence – • Moves to assemble the parts Measurements – • Areas to analyze during simulation
  16. 16. Dimensional Control Systems | 2017 All Rights Reserved Spec Study & Visualization Determine Gap and Build Objectives Before Engineering (what is max and min tolerance objectives) See How Variation Affects the Product’s Appearance (Perceived Quality)
  17. 17. Dimensional Control Systems | 2017 All Rights Reserved Part Geometry Nominal Part Geometry, Tolerances and GD&T - Apply FTA (embedded GD&T) - Point tolerances in 3DCS - Feature tolerances in 3DCS - Tooling tolerances (influence on design)
  18. 18. Dimensional Control Systems | 2017 All Rights Reserved CATIA GD&T FTA Extraction and Updating • 3DCS models can be created faster and with less errors by extracting CATIA FTA • Part and Assembly GD&T FTA is supported. • No need to re-author data
  19. 19. Dimensional Control Systems | 2017 All Rights Reserved Assembly Sequence • The Assembly Sequence determines how parts locate to one another and in what order. • In 3DCS, a "move" defines how a part is located in space. • Moves are added to the model to represent each step in the build process. A move reflects how the variation of the locating features is transmitted through to a product.
  20. 20. Dimensional Control Systems | 2017 All Rights Reserved Measurements • They aid in understanding the effects of 3D tolerance stack ups. • Measurements are used to determine how critical dimensions in an assembly are affected by fixture and part tolerances. • Both points on a surface or the feature itself can be used to define a measurement. Measurements quantify the variation of the desired output in the model.
  21. 21. Dimensional Control Systems | 2017 All Rights Reserved Reporting • Push Button Summary of Your Model Inputs and Outputs • Automatically Created in Html or Excel
  22. 22. Dimensional Control Systems | 2017 All Rights Reserved Additional Features Color Mapping – Use Color Mapping to quickly see trouble areas and communicate with managers and teams Alias Display – Change the names of your model features to make it easier to use, then when you are done, change them bac Process Capability Database PCDB – Connect your tolerances to a database of known processes or plant data Embedded GD&T – Use CAD based GD&T to quickly test designs and create models Optimization – Use wizards to optimize and rerun analyses to see the effect of design changes Specialized Tools
  23. 23. Dimensional Control Systems | 2017 All Rights Reserved CATIA Rendering • 3DCS allows users to visualize extreme Gap and Flush conditions and then they can be visualized in real time with the Creo Rendering engine
  24. 24. Dimensional Control Systems | 2017 All Rights Reserved 3DCS ADD-ON MODULES Expand your 3DCS software
  25. 25. Dimensional Control Systems | 2017 All Rights Reserved FEA Compliant Modeler  Determine the effect of flexible materials during manufacturing processes (aluminum, sheet metal, plastic)  Apply forces to your parts and determine the impact on overall variation  Optimize processes like welding sequences, riveting, bolting and tooling  Incorporate Finite Element Analysis into your Tolerance Analysis all in one software
  26. 26. Dimensional Control Systems | 2017 All Rights Reserved Mechanical Modeler  Incorporate kinematic and mechanical moves into your model  Use Joints and Constraints from CAD or a built in library  Use Degree of Freedom Counter to determine constraints and validate models
  27. 27. Dimensional Control Systems | 2017 All Rights Reserved Assembly Constraint and Joint Extraction • 3DCS Mechanical models can be created faster and with less errors by extracting Creo Assembly Constraints & Joints to create Mechanical Moves • No Re-authoring data
  28. 28. Dimensional Control Systems | 2017 All Rights Reserved AAO – Advanced Analyzer Optimizer  Analyzers to quickly work with large models and get a global view of variation  Optimizers to determine optimum tolerances and designs  Locator Sensitivity Analyzer to test locator schemes and determine the best options
  29. 29. Dimensional Control Systems | 2017 All Rights Reserved Visualization Export  Output fbx files to create seamless workflows with high end visualization tools (Deltagen, VRED, Showcase)  Turn your model into life like visual images to showcase how the actual product will appear with given design specification
  30. 30. Dimensional Control Systems | 2017 All Rights Reserved Inspection Planner  Create inspection and measurement places from your CAD data  Use within the CAD platform to create reusable templates to analyze plant and CAD data  Use to bring plant data seamlessly into CAD
  31. 31. Dimensional Control Systems | 2017 All Rights Reserved WHO USES 3DCS? Customer Stories
  32. 32. Dimensional Control Systems | 2017 All Rights Reserved Companies Across the Globe Use 3DCS FIAT CHRYSLER AUTOMOBILES AIRBUS LG ELECTRONICS GENERAL MOTORS THE BOEING COMPANY PHILIPS VOLKSWAGON EMBRAER MAGNA BMW BOMBARDIER SAMSUNG ELECTRONICS JAGUAR LAND ROVER LOCKHEED MARTIN WHIRLPOOL AUTOLIV CESSNA TEXTRON MERITOR VALEO FAURECIA PETERBILT LENOVO TESLA GE DAIMLER DURA AUTOMOTIVE SYSTEMS KENWORTH SONY GULFSTREAM TOYOTA NISSAN ELECTROLUX LEXMARK  Used by major OEM’s and Suppliers across the world  Industry standard tolerance analysis tool in the automotive and aerospace industries  More than 400 companies worldwide use 3DCS
  33. 33. Dimensional Control Systems | 2017 All Rights Reserved EXAMPLE APPLICATIONS
  34. 34. Dimensional Control Systems | 2017 All Rights Reserved General Motors Results… "Successful tolerance analysis product execution played a major role in our achievement of high quality across our product vehicle line. The Chevrolet Volt, Chevrolet Silverado, Chevrolet Malibu and Cadillac CTS were all named Car/Truck of the Year winners." Richard Korynski Body Tolerance Analysis Manager-General Motors
  35. 35. Dimensional Control Systems | 2017 All Rights Reserved General Motors Results… DCS… The Ecotec program used 3DCS analysis. Moreso than other engine programs, although that is quickly changing as more engineers are realizing its benefits. Use of 3DCS on all engine programs has increased dramatically over the past two years. 3DCS was used in such studies as ... Engine Combustion Variation (compression ratio) Accessory Drive Belt System Chain Drive and Valvetrain kinematics Direct-Injection Fuel Injection System Studies in Sensor Variation Many packaging/clearance studies between components Interface/Joint studies between components (fasteners and port alignments) In-vehicle engine compartment packaging Cordially, E.M. GM Powertrain Engine Design L850 Tolerance Analysis Lead
  36. 36. Dimensional Control Systems | 2017 All Rights Reserved Daimler Results…  Tolerance Planning is the Way to Improve Product Quality  3D Tolerance Simulation is a suitable Tool to evaluate and improve Tolerance Concept  We took Benefit from using 3DCS in a first Car Project  There is still Potential in reducing the Efforts & Costs for the Modeling itself  Therefore we will especially work with 3DCS to further enhance - Performance & Robustness - CATIA V5 Integration Dr. Alexander Layer & Hansjörg Ströhle Daimler AG
  37. 37. Dimensional Control Systems | 2017 All Rights Reserved Chrysler Results “New Metrology Culture Improving Chrysler Quality” SME Magazine “Five years ago, our fit and finish was below average,” said Dr. Raj Kawlra, director of dimensional strategy and management of Chrysler Group (Auburn Hills, MI). “To be the future world-leaders, we knew that we had to focus on all aspects of quality … vehicles that look good, feel good, sound good, and are reliable.” Link to article: http://www.sme.org/MEMagazine/Article.aspx?id=77027
  38. 38. Dimensional Control Systems | 2017 All Rights Reserved LG Case Study DO NOT DISTRIBUTE
  39. 39. Dimensional Control Systems | 2017 All Rights Reserved Embraer The main purpose of the tolerance analysis was to assure and improve final product quality. The analysis results justified the need of design changes to accommodate dimensional variation. The amount of predicted variation identified the need to change gap and seal specifications as well as helped optimize hinge designs to guarantee no pre-stress and increased product life. The software also supported the definition of pre-manufactured shims now used in production. 3DCS also helped Embraer find possibilities to use “coordinated assembly” minimizing tooling which lowered production costs with guaranteed product quality. Additionally, tolerance analysis and simulation techniques motivated and supported process development strategies to guarantee process variation compensation on composite tooling design. Daniel C. da Silva, Embraer Tolerance Analysis Team Leader “The 3DCS technology brought our commitment to product quality and safety by design to an even higher level. The tool not only can quantify our technical decisions but truly helps our IPD teams to numerically and visually discuss spatial dimensional variations and its management early in the design phase. These facts, together with an integrated Catia V5 environment, intensive technical training and the DCS top support and development service were the key to our success in this custom development for JetBlue, one of our key EMBRAER 190 customers.” “The Live TV Radome (radar dome) is used to protect the antenna, which sits on top of the E190 fuselage. The structural Radome assembly consists of about 50 parts with over 150 key tolerance specifications. It was Embraer’s first production usage of 3DCS … software on a totally new development project.” Live TV Radom Variation Study
  40. 40. Dimensional Control Systems | 2017 All Rights Reserved Case Study: Embraer Throughout the process, the mantra was ‘more for less’… The GD&T we used to develop this final interior has enabled the best craftsmanship and cabin experience in the industry - Jay Beever, vice president of marketing and interior design at Embraer “ ” “ ” Legacy 450 and 500 Business Jet Interiors international April 2014
  41. 41. Dimensional Control Systems | 2017 All Rights Reserved Legacy 450 and 500 Interior Parker, Selwyn. "Legacy 450 and 500." Business Jet Interiors International April (2014): 60-66. Business Jet Interiors International. UKIP Media & Events Ltd, Apr. 2014. Web. “In this a key element was a process known as geometric dimensioning and tolerancing (GD&T) that, broadly speaking, tells manufacturing staff the exact degree of precision required on each controlled feature of the assembly” (Parker 2014, p. 62). “…the sideledge lids and storage bins are so precisely engineered that they operate almost like jewelry boxes.” Business Jet Interiors International, pg 63
  42. 42. Dimensional Control Systems | 2017 All Rights Reserved Boeing 8A Poseidon • Radar attachment points • Designed in parallel with refit • Given two points in space to design to. • Final product ‘clicked’ into place. http://www.boeing.com/boeing/defense-space/military/p8a/
  43. 43. Dimensional Control Systems | 2017 All Rights Reserved Case Study: AN/APY-10 Radar • 2 Initial Locators Given • Design Composed Parallel with Aircraft • Variation analysis to determine necessary characteristics Parallel Design and Testing Locator Points for Assembly http://www.raytheon.com/capabilities/products/apy10/
  44. 44. Dimensional Control Systems | 2017 All Rights Reserved Airbus Issue: Shimming at final assembly increasing weight and decreasing fuel efficiency. Challenge: Determine key characteristics at attachment points and reduce assembly variation. Solution: Dimensional Analysis with 3DCS assisted in improving build strategy and controlling variation at primary connection points. Results: Total shimming reduced by 40% in aircraft assembly. Analysis to Reduce Aircraft Assembly Shimming
  45. 45. Dimensional Control Systems | 2017 All Rights Reserved Airbus Feedback Loops
  46. 46. Dimensional Control Systems | 2017 All Rights Reserved Case Study: ITER TOKAMAK
  47. 47. Dimensional Control Systems | 2017 All Rights Reserved Toroidal Field Coils Self Supporting Electro Magnets Fit Like ‘Orange’ Slices Keystone Piece Imperative Fusion Reactor
  48. 48. Dimensional Control Systems | 2017 All Rights Reserved Consumer Electronics Laptop Internal Component Variation Analysis Issue: Variation of Internal components of laptop causing assembly build issues – hard drive, mother board, ram chips, etc… - Limited space inside of Laptop case creates very little room for variation. Changes in components from manufacturing variation were causing cases where the components did not all fit inside the case. Solution: Simulating the assembly sequence with variation taken into account provided new insight into the source of the variation and primary trouble areas. Results: With basic design changes to the placement of the components, the current amount of variation was accounted for, requiring very little adjustment in tolerances.
  49. 49. Dimensional Control Systems | 2017 All Rights Reserved Consumer Electronics Issue: Variation in lens connections causing build issues. Solution: Simulation in 3CS of assembly determined contributor and true cause of variation. Results: Basic design change and simulation validation produced a reduction in overall assembly variation, greatly reducing the chance of assembly build failures. Demonstration Model Only Camera Fit Analysis
  50. 50. Dimensional Control Systems | 2017 All Rights Reserved Transportation Snowmobile Shock Analysis Issue: Shock was freezing up when placed under larger forces, such as a jump or heavy landing. Solution: Using 3DCS Mechanical, the shock was simulated with variation from manufacturing as well as assembly processes and through a large range of different forces. Results: At higher levels of force, the shock was seizing from a variation build up connecting with the spring system. This was unforeseen as it stemmed more from process than part tolerancing. A minor adjustment to the process negated the problem, using simulation to validate.
  51. 51. Dimensional Control Systems | 2017 All Rights Reserved Results: Choosing the best option, for manufacture and assemble-ability, as well as appearance, the customer was able to determine a design change to the hole/pin attachment at the rear of the drawer that allowed for enough float to keep tolerances from being too tight, while not sacrificing the drawers function and appearance. Medical Device Drawer fit and function Medical Defibrillator Drawer Analysis Issue: Front drawer of the device did not fit properly during assembly. Solution: 3DCS was used to simulate the variation and perform iterative analyses on possible solutions. These were compared, using Spec Studies to determine the appearance of each solution.
  52. 52. Dimensional Control Systems | 2017 All Rights Reserved Home Goods Demo Model Only Customer Model Not Shown Washer Dryer Spec Study and High End Visualization Issue: Customer was concerned that the current design, when built, may have offset components such as doors, buttons or control nobs at extreme tolerance situations (ie. One side at maximum condition, and one side at minimum condition). Solution: High End Visualization was added to various scenarios using design tolerances to show possible extremes. Results: Customer modified some tolerances in order to reduce the chance of certain scenarios while leaving others the same due to lack of change to product appearance.
  53. 53. Dimensional Control Systems | 2017 All Rights Reserved Ship Building Crane Internal Mechanisms Issue: Mechanical components of the crane Inside the ship are having functional issues. Solution: 3DCS Mechanical was used to analyze the assembly and through its entire range of motion, determining possibility of out of spec conditions. Results: Adjustments from general tolerances to specific ones for various components reduced the possibility of out of spec conditions.
  54. 54. Dimensional Control Systems | 2017 All Rights Reserved Heavy Machinery Boxcutter Assembly Analysis Issue: Optimization of tolerances for less expensive manufacturing while retaining full functionality. Solution: AAO, Advanced Analyzer and Optimizer, was used to quickly determine key tolerances and critical areas. Results: Using AAO, tolerances and features that were not key to quality had their tolerances opened up, while key areas were tightened to improve assemble-ability. This overall reduction in manufacturing costs had a positive outcome on overall product cost.

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