Parametric Master Model for N-Step Manufacturing Error Management
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Solution Overview
Problem
In N-step manufacturing processes, the accumulation of errors across successive manufacturing steps requires frequent updates to CAD design models and process plans, leading to increased personnel costs and data storage requirements due to the need for generating new models and plans at each step.
Innovation Solution
A parametric master model is created to represent the mechanical part, which is updated after each manufacturing step based on received parameter values and planned variations, allowing for automatic updates of process plans without the need for new design models at each step, using a computer system with executable instructions for creating and updating the model and plans.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If new CAD design models and process plans are generated at each manufacturing step, then manufacturing precision is maintained through error management, but personnel costs and data storage requirements increase
Solution Approach 1:
The patent merges multiple separate CAD design models into a single master model that is updated iteratively through the manufacturing process. Instead of generating new models at each step, the system maintains one evolving model that incorporates error corrections, thereby reducing data storage requirements while preserving manufacturing precision.
Solution Approach 2:
The system uses parameter changes to update the master model efficiently. By modifying specific geometric parameters and tolerance values in the existing model rather than creating new models, the system maintains manufacturing precision while minimizing the generation of new data files, thus reducing storage requirements.
2Manufacturing precision
If new CAD design models and process plans are generated at each manufacturing step, then manufacturing precision is maintained through error management, but personnel costs increase
Solution Approach 1:
The system implements self-service through automated error detection and model updating. The computer system automatically calculates accumulated errors, adjusts the master model parameters, and generates updated process plans without requiring manual intervention at each manufacturing step, thereby reducing personnel costs while maintaining precision.
Solution Approach 2:
The system uses feedback from actual manufacturing measurements to continuously update the master model. By incorporating real-time error data from previous steps into the model updates, the system maintains manufacturing precision through an automated feedback loop, eliminating the need for manual model regeneration and reducing personnel involvement.
3Manufacturing precision
If the master model is updated based on accumulated errors, then manufacturing precision is maintained, but the complexity of model management increases
Solution Approach 1:
The patent replaces manual model management mechanisms with automated computer-based systems. The computer system automatically tracks accumulated errors, calculates necessary parameter adjustments, and updates the master model without manual intervention, thereby maintaining precision while reducing the complexity of model management through automation.
Data Source
AI summary
A method for efficiently implementing an N-step manufacturing process for producing a mechanical part may include creating a parametric master model that represents a part to be produced in an N-step manufacturing process. The method may also include using the parametric master model to create process plans for the N-step manufacturing process. After manufacturing step i of the N-step manufacturing process, the method may include receiving information concerning values of parameters in the parametric master model as they exist after manufacturing step i of the N-step manufacturing process. Updates to the parametric master model may be made based on the information that was received. The process plans corresponding to manufacturing step i+1 of the N-step manufacturing process may be updated based on the updated parametric master model.