Virtual Assembly Build Instructions for Early Issue Detection
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Solution Overview
Problem
The traditional manufacturing process lacks an efficient method to translate the 3D design of assemblies into actionable build instructions, often leading to assembly issues and the need for extensive manual assembly manuals.
Innovation Solution
A virtual build tool operates within design software to generate build instructions based on sequence numbers and images, allowing for a virtual assembly process that identifies potential issues and creates detailed physical manufacturing guidelines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manual processes are used to create assembly manuals, then extensive manual effort and time are required, but the process is not specifically linked to the design environment and assembly issues are discovered too late
Solution Approach 1:
The system performs preliminary actions by automatically generating assembly instructions and detecting potential assembly issues during the design phase, before physical manufacturing begins. The virtual build tool simulates the assembly process and identifies fit and compatibility problems early, preventing delays during actual manufacturing.
Solution Approach 2:
The system creates a virtual copy of the physical assembly process through digital simulation. The virtual build tool generates digital assembly instructions and detects issues in a virtual environment, eliminating the need for extensive manual creation of assembly manuals and allowing issue detection before physical manufacturing.
2Productivity
If physical manufacturing is performed without virtual build simulation, then assembly issues are discovered during production, but extensive manual processes and delayed issue detection occur
Solution Approach 1:
The system performs preliminary detection of assembly issues through virtual build simulation before physical manufacturing. The tool analyzes the 3D model to identify fit and compatibility problems in advance, making issue detection easier and preventing production delays.
Solution Approach 2:
The system replaces manual mechanical inspection processes with automated digital analysis. The virtual build tool uses computer-based simulation and analysis to detect assembly issues, substituting manual detection methods with automated digital systems that are more efficient and accurate.
3Ease of operation
If extensive manual assembly manuals are created, then detailed instructions can be provided, but the process is time-consuming and not integrated with the design environment
Solution Approach 1:
The system automatically generates assembly instructions by copying and processing data from the existing 3D design model. This eliminates the need for manual creation of assembly manuals while maintaining integration with the design environment, as the instructions are derived directly from the digital model.
Solution Approach 2:
The system performs self-service by automatically generating assembly instructions and detecting issues without requiring extensive manual intervention. The virtual build tool processes the 3D model data and produces assembly guidance autonomously, reducing the complexity of the manual creation process.
Data Source
AI summary
A virtual build of an assembly may be performed by operating a virtual build tool inside of an active session of design software that is configured to design an assembly having multiple individual parts; importing characteristics of the assembly from a three-dimensional (3D) model of the assembly that is maintained by the design software; receiving an input of sequence numbers that indicate an assembly order for the individual parts; generating images for the individual parts as they are incrementally added to the assembly based on the sequence numbers; and generating a set of build instructions based on the sequence numbers and the images for the individual parts, where the set of build instructions illustrate how to physically manufacture the assembly.