Vehicle Assembly

      3DCS - Three-Dimensional Deviation Analysis Specialist——Graphical tolerance simulation software.3DCS is the most advanced dimensional deviation analysis tool used to simulate the design, manufacture and assembly of the product, predicting the amount of deviation inherent in the design and determining the source of the deviation.3DCS provides the necessary tolerance analysis methods to predict process changes in an assembly ,identifies the source of additional changes and improves the stableness of the design.Ultimately,enabling users to analyze and optimize designs to improve quality and reduce costs early in the design phase.


Background and status

  •  The Assembly precision of the vehicle not only affects the quality, but impacts the  manufacturing cost .However, in the traditional design and manufacturing , the tolerance design and allocation are mainly based on experience or reference to other benchmark models.Then, In the later trial production process, continuous alignment is carried out to  meet the assembly requirements. Due to the deviation source in the design and assembly is not found, and the Assembly gap is too large and flush is out of tolerance or even interference in the actual assembly process. The enterprise often uses the method of amplifying the tolerance or lowering the appearance standard to compromise. Meanwhile,Enterprises for dimension is extensive management, lack of modeling design familial,  structural design modularization, process standardization, dimensional chain analysis system. result in the CPMP, assembly quality is low, development cycle is long and production costs is high.


Solution scheme

  •  In the process of vehicle assembly deviation analysis, users introduce advanced three-dimensional deviation analysis tool 3DCS Variation Analyst, and complete the design objectives of the stages in each node of CPMP:

     1、Pre-PA:make the detailed work plan in the CPMP, and creat the perceived quality to meet the customer's needs according to the analysis of competitive vehicle, modeling needs, process capability and others;

     2、Design Stage: establish deviation analysis model to evaluate and verify the risk of positioning strategy and tolerance setting,modify DTS, judge assembly error and deviation source, optimize structure and process design;

     3、Pilot Stage: develop reliable measurement plan and system to monitor dimensional fluctuation and quickly deal with dimension problems;

    4、MP Stage:componts,sub-assemblies, white body welding assembly detection,process capability evaluation and functional dimention control, as well as associated plant database to achieve the creation of closed-loop quality deviation Analysis System.


Advantages and features

  •  In the design and assembly of vehicle , the use of 3DCS Variation Analyst for three-dimensional deviation analysis can ensure the reliability of the design ,meanwhile, greatly improve the design efficiency, compress the project development cycle, and has the following features and advantages:

1、Optimize product design and process

     uAllows 3DCS users to pre-evaluate design and assembly concepts and identify possible problems early stage in product development. 

     uOptimize critical quality characteristics, allowing users to enhance the analysis of critical area tolerances and structural process adjustment.

2、Shorten time cycles and reduce rework costs

     uUsing process capability database and product manufacturing capability to create digital virtual prototype. 

     uThe virtual prototype simulation  is used to reduce the physical prototype ,thus reducing the cost, shortening the development time, and accelerating the product delivery to the market.

3、Identify critical contributor

     uMeet the size requirements while maximizing the tolerances of the parts, reducing rework of tools and instruments, minimizing scrap, reducing defects, and thus reducing manufacturing  costs. 

     uBefore the design is released to the entire process of the product, the use of 3DCS  to check the function and assembly of components, ensuring the minimum requirements and significantly improve product quality.  

4、Continuous improvement in quality

     uCreating a closed-loop quality deviation analysis system for associated plant data, fully evaluate the pre-design and post-manufacturing, and establish the enterprise process capability Library. 

     uCreating a  mechanism for data-driven production.