3D Tolerance Analysis Using Overlay Surfaces
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Solution Overview
Problem
Manufacturers face challenges in making accurate and consistent disposition decisions for nonconforming components during the manufacturing process due to time and cost constraints, often relying on historical experience and improvisation, leading to issues like recalls, warranty repairs, and excess scrap.
Innovation Solution
A computer-aided design system that provides tolerance analysis by simulating the variation of model assemblies, identifying user-selected surfaces, applying constraints, and determining the relative contribution of each surface to the stack, allowing for precise modification of tolerance values to maintain assembly integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manufacturers rely on historical experience and improvised handwork solutions for disposition decisions, then decision-making speed is improved, but accuracy and consistency of disposition decisions deteriorate
Solution Approach 1:
The patent replaces manual, experience-based disposition decision-making with an automated computer-based system that uses measurement data, constraints, and simulations to objectively determine whether nonconforming components can be reworked or must be scrapped, eliminating reliance on subjective historical experience
Solution Approach 2:
The system enables manufacturers to perform their own tolerance analysis and disposition decisions using automated computational methods, replacing the need for external expertise or subjective judgment with self-contained technical analysis capabilities
2Measurement precision
If manufacturers perform detailed tolerance analysis on model assemblies, then disposition decision accuracy is improved, but computational complexity and time requirements worsen
Solution Approach 1:
The patent segments the tolerance analysis process into distinct computational components: defining constraints between components, creating overlay surfaces for measurement, performing simulations, and generating reports. This modular approach manages complexity by breaking down the overall analysis into manageable, automated steps
Solution Approach 2:
The system creates virtual copies of the physical assembly through digital model assemblies and overlay surfaces that represent measurement data. These digital representations allow for repeated, rapid simulations without physical prototypes, reducing the complexity of physical testing while maintaining analysis accuracy
3Reliability
If manufacturers use automated tolerance analysis systems, then disposition decision consistency is improved, but implementation cost and system complexity worsen
Solution Approach 1:
The patent creates a universal computer-based system that can handle multiple disposition decision scenarios across different components and assemblies. The same software platform and methodology apply universally to various nonconforming component evaluations, ensuring consistent decision-making criteria regardless of the specific part or defect type
Solution Approach 2:
The system uses measurable parameters from actual component inspections (overlay surface measurements, constraint relationships, stack variations) to objectively determine disposition decisions. By basing decisions on quantifiable parameter changes rather than subjective judgment, the system achieves high consistency and reliability across different operators and scenarios
Data Source
AI summary
A computer-aided design system provides tolerance analysis of model assemblies. Constraints are applied to a model assembly based on user-selected surfaces. Overlay surfaces are defined at the assembly, where each of the overlay surfaces corresponds to a user-selected surface. One or more stacks are defined based on a user input, where the stacks are a measurement dimension encompassing two or more parts of the assembly. The system simulates 1) variation of the overlay surfaces across a range of variation values within a respective tolerance zone based on the tolerance specifications, and 2) alteration of the stack as a result of the variation. Based on the variation of the overlay surfaces, the system identifies a subset of the user-selected surfaces that, when varied within the respective tolerance zone, alter the stack. A database is configured to indicate 1) the user-selected surfaces and 2) respective contributor values indicating a relative contribution of each of the user-selected surfaces to the stack.