Virtual FE Inspection of Produced Parts Under Mounting Constraints
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Solution Overview
Problem
Existing physical inspection fixtures for thin-walled components in automotive assembly are expensive, time-consuming to produce, occupy valuable space, and introduce errors due to manufacturing imperfections, while being inflexible and requiring costly logistics for global part shipment and adjustment.
Innovation Solution
A virtual checking fixture is created using Finite Element analysis, simulating the effects of mounting restraints and gravity on actual parts, allowing for flexible constraint adjustment and virtual assembly simulation without physical fixtures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical holding fixtures are used to constrain and inspect thin-walled parts, then measurement precision and part constraint are improved, but manufacturing cost and production lead time increase significantly
Solution Approach 1:
The patent creates a virtual fixture model in advance that simulates the constraint conditions of physical fixtures. This virtual model is prepared beforehand and can be used repeatedly for inspection without physical manufacturing lead times, allowing inspection planning and simulation to be completed prior to actual part production or arrival.
Solution Approach 2:
The patent creates a digital copy (virtual fixture) that replicates the functionality of physical fixtures. This virtual copy includes mounting restraints and constraint conditions that mirror the physical fixture's behavior, allowing inspection simulations without requiring the actual physical fixture to be manufactured and transported.
2Measurement precision
If physical checking fixtures are manufactured to high accuracy standards, then measurement precision is improved, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent replaces complex physical fixture manufacturing with digital model creation. The virtual fixture is defined through software parameters and digital geometry, eliminating the need for precision machining, assembly, and calibration of physical components while maintaining the same constraint and measurement capabilities.
Solution Approach 2:
The patent substitutes the mechanical physical fixture system with a computational virtual fixture system. Instead of relying on physical mounting restraints and mechanical constraint structures, the system uses software-based constraint models and numerical simulations to achieve the same inspection objectives with reduced complexity.
3Adaptability or versatility
If physical fixtures are used to simulate systematic production errors, then adaptability is improved, but fixture adjustment time and complexity increase
Solution Approach 1:
The patent implements a dynamic virtual fixture system where constraint parameters, mounting positions, and restraint conditions can be modified in real-time through software. This allows the virtual fixture to adapt to different inspection scenarios, including systematic production errors, without any physical adjustment or reconfiguration, providing full flexibility through digital parameter changes.
4Measurement precision
If parts are shipped globally to assembly factories for inspection, then measurement capability is improved, but logistics cost and loss of time increase
Solution Approach 1:
The patent enables inspection capabilities to be replicated digitally at the supplier's location through the virtual fixture system. Suppliers can perform inspections using their own measurement equipment and the OEM's virtual fixture models, eliminating the need to physically transport parts to the assembly factory for inspection while maintaining measurement accuracy and capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Reduces production lead times, saves costs, and enhances flexibility in part inspection and assembly by eliminating the need for physical fixtures, enabling remote evaluation and rapid feedback on part quality.
Implementation Method 1
A clean Finite Element-mesh of an actual produced part is created by measuring the part to generate a three-dimensional numerical representation of the actual produced part
Implementation Method 2
Within the FE analysis, further steps may be applying a gravity force to the constrained actual produced part, and determining the deformation of the actual FE mesh further resulting from the gravity force
Implementation Method 3
A three-dimensional point cloud being a numerical representation of the actual produced part is recorded by three-dimensionally measuring the actual produced part
Data Source
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AI summary
The invention relates to a method and a computer programme product for virtually inspecting an actual produced part, comprising providing an ideal Finite Element (FE)-mesh corresponding to an ideal produced part, said ideal produced part comprising two or more mounting places, by measuring the actual produced part, generating a numerical representation of the actual produced part, generating an actual FE-mesh by modifying the ideal FE-mesh such that the shape of the ideal FE-mesh adapts to the numerical representation of the actual produced part, within an FE-analysis, forcing the actual FE-mesh into position by constraining the mounting places of the actual FE-mesh, determining a deformation of the actual FE mesh resulting from its constraint.