polyworks conference usa 2017, novi, mi improving ... · pdf fileimprove dimensional analysis...
TRANSCRIPT
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Copyright 2017 Tesla Motors, Inc. 1
Polyworks Conference USA 2017,
Novi, MI
Improving Dimensional Analysis
within Polyworks through GD&T
Mathieu Desjardins,
Sr. Dimensional Engineer
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Copyright 2017 Tesla Motors, Inc. 2
INTRODUCTION
Associate’s degree in
Aerospace Design
engineering (3 years)
Bachelor’s degree in
Mechanical engineering
(4+ years)
NO METROLOGY OR GD&T TRAINING
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Copyright 2017 Tesla Motors, Inc. 3
INTRODUCTION
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Copyright 2017 Tesla Motors, Inc. 4
INTRODUCTION
Career path:
Amrikart Inc.: First Metrology experience. Quickly became supervisor
of the metrology team, supporting and training up to 8
technicians
Ex Dimensional engineer specialized in 3D metrology and
GD&T analysis
Bombardier Industrialization Metrology engineer, specialized in
metrology training and GD&T support for all
Bombardier North American’s quality teams
Tesla Sr. Dimensional Engineer in a task force team as
the GD&T, tool design and 3D metrology expert
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Copyright 2017 Tesla Motors, Inc. 5
INTRODUCTION
“To accelerate the world’s
transition to sustainable
transportation.”
Tesla’s Mission
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Copyright 2017 Tesla Motors, Inc. 6
INTRODUCTION
About TeslaTHE TESLA ROADSTER
– hit the streets in early 2008 as a sport car
– It go from 0 to 60 mph in 3.7 seconds and travel for 245
miles per charge.
– About 2,450 Roadster has
been sold in 30 different
countries.
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Copyright 2017 Tesla Motors, Inc. 7
INTRODUCTION
MODEL S
– arrived in 2012
– A premium sedan that goes from 0 to 60 mph in 2.5 seconds and
travels over 300 miles per charge
– Full Self-Driving Hardware
– More than 150,000 cars
sold
About Tesla
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Copyright 2017 Tesla Motors, Inc. 8
INTRODUCTION
MODEL X– All-Wheel drive and a 100 kWh battery providing 295
miles of range
– A crossover utility vehicle that blends the best of an SUV with the benefits of a minivan.
– With Ludicrous mode, accelerating from 0 to 60 mph in a quick 2.9 seconds.
– Full Self-Driving Hardware
About Tesla
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Copyright 2017 Tesla Motors, Inc. 9
INTRODUCTION
MODEL 3
– Combines real world range,
performance, safety and
spaciousness into a premium
sedan
– To achieve 215 miles of range
per charge.
– Starting price at only $35,000
before incentives
– Full Self-Driving hardware
– 0 to 60 mph under 6 sec
About Tesla
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Copyright 2017 Tesla Motors, Inc. 10
INTRODUCTION
About TeslaTESLA ENERGY (Merged with Solar City)
– Power from above, beauty from the street.
New rooftop solar tiles to power your home
with clean, renewable energy.
– Combine to Tesla’s Powerwall, the home
battery can stores unused solar energy and
provide freedom from the utility grid.
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Copyright 2017 Tesla Motors, Inc. 11
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
MAIN PRESENTATION SUMMARY
• Example 1: Use of GD&T tool in Polyworks to better reflect 2D
drawing requirement.
• Example 2: Feature reference target versus Datum reference
frame alignment
• Conclusion
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Copyright 2017 Tesla Motors, Inc. 12
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
EXAMPLE 1:
USE OF GD&T TOOL IN POLYWORKS
TO BETTER REFLECT 2D DRAWING
REQUIREMENT
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Copyright 2017 Tesla Motors, Inc. 13
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
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Copyright 2017 Tesla Motors, Inc. 14
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
1
2
3
4
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Copyright 2017 Tesla Motors, Inc. 15
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
56
7
8
9
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Copyright 2017 Tesla Motors, Inc. 16
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
1
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Copyright 2017 Tesla Motors, Inc. 17
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
1 Datum A
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Copyright 2017 Tesla Motors, Inc. 18
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
1 Datum A
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Copyright 2017 Tesla Motors, Inc. 19
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
2
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Copyright 2017 Tesla Motors, Inc. 20
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
2 Datum A
Surface
Profile
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Copyright 2017 Tesla Motors, Inc. 21
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
3
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Copyright 2017 Tesla Motors, Inc. 22
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
3 Datum B
Pattern of 3
Cylinders
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Copyright 2017 Tesla Motors, Inc. 23
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
4
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Copyright 2017 Tesla Motors, Inc. 24
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
4 Surface
profile all
around
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Copyright 2017 Tesla Motors, Inc. 25
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
5
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Copyright 2017 Tesla Motors, Inc. 26
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
5 Datum D
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Copyright 2017 Tesla Motors, Inc. 27
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
6
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Copyright 2017 Tesla Motors, Inc. 28
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
6 Datum E
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
6 Datum E
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
7
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Copyright 2017 Tesla Motors, Inc. 31
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
7 Datum F
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Copyright 2017 Tesla Motors, Inc. 32
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
8
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
8 Circle 1
True
Position
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
9
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Example 1
9 Plane 1
with
Unilateral
Surface
Profile
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Copyright 2017 Tesla Motors, Inc. 36
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
EXAMPLE 2:
FEATURE REFERENCE TARGET VS
DATUM REFERENCE FRAME
ALIGNMENT
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Feature Reference Target versus Datum Reference Frame Alignment
Issue: Glass part doesn’t fit into the 3
holes.
Initial Root Cause: Either the body
holes position are out of tolerance, or
the pins position are out of tolerance.
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Feature Reference Target versus Datum Reference Frame Alignment
GD&T Engineering requirement
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Reference Feature Target Alignment
Using non-GD&T
Workflow, the
reference target
were ususally the best
option. Manually
defining the
alignment direction
using the World csys.
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Reference Feature Target Alignment
Reporting looks easy
since the B datum is
X=0 and Z=0. Datum
C is also Z=0.
Alignment looks good
and circle 3 pass the
± 1.5mm in each
direction.
All this using the World
(body) coordinate
system.
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Reference Feature Target Alignment
The Body X-Y-Z
coordinate system
are not squared with
the alignment
direction defined by
each reference
target.
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Reference Feature Target Alignment
Since the alignment
direction for the slot was Z,
the Z coordinate of the
nominal and measured slots
are matched and leads to
a 0 deviaiton along that
axis.
But a deviation of 1.582
remains along Y in between
the nominal and meausred
slots.
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Reference Feature Target Alignment
View Normal to ZX Plane
View normal to Datum A
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Copyright 2017 Tesla Motors, Inc. 44
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Datum Reference Frame Alignment
Now, using the GD&T
workflow and by
using real datum
targets to make the
alignment, Circle 3
fails.
AND, Datum C is now
not 0 in Z, but
0.580mm.
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Copyright 2017 Tesla Motors, Inc. 45
IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Datum Reference Frame Alignment
Using DRF Alignment,
Polyworks aligned the two
slots simulating the biggest
pin that can fit in the two
features.
Y deviation is now 1.483mm
and Z deviation is now
0.580mm
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Datum Reference Frame Alignment
View Normal to ZX Plane
View normal to Datum A
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
Datum Reference Frame Alignment
If aligned correctly
using the datum
reference frame,
Circle 3 is now out of
tolerance.
Body hole has been
relocated using this
deviation result and
now the supplier part
fit to the body.
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IMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS
CONCLUSION
• Polyworks really improve dimensional analysis by using the right DRF
alignment and can save time in finding root cause.
• Polyworks also simplify the 2D drawing analysis using GD&T requirement
and creating exactly the same engineering callout for reporting.
• Improve communication between the inspector and the quality engineer
by using same language to report deviation.