CATIA Integrated Tolerance Analysis - 3DCS for CATIA V5

Dimensional Control Systems | 2017 All Rights Reserved
3DCS Variation Analyst for CATIA
Tolerance Analysis Software fully integrated
into Dassault Systemes CATIA CAD Platform

3DCS Fully Integrated in CATIA
• 3DCS Model is stored in CATProducts
• Utilize any PLM system that stores your CATIA Model
• Support for CATIA V5-6, R19-26, including R2014,2015,2016
• Point and Feature Based modeling
• Use Enhanced Scenes to create scenarios
• No loss of data through translation.
• Measurement Point Coordination between CAD and 3DCS
• Extract and use CATIA GD&T (FTA) and Joints and Constraints

What is 3DCS Variation Analyst?
CAD based tolerance and process analysis software
Integrated Into:
Dassault Systemes CATIA V5-6
CATIA 3DEXPERIENCE
Siemens NX
PTC Creo
Available also in a
CAD neutral stand
alone version

What is a Variation Analyst Model?
A CAD model that incorporates part tolerances, assembly process and inspection
measurements inside 3DCS software

Why Use 3DCS?
Determine how part and assembly tolerances affect the overall build and fit of a product.
Will my current design work? How well?
Where should I measure in production?
Where will I have manufacturing problems specifically?
How will tooling affect my product?
Can I change the assembly process to reduce variation?
How do I fix variation issues?
Get Answers:

3DCS Inputs
Part Geometry –
GD&T and Tolerances
Assembly Sequence –
Moves to assemble the parts
Measurements –
Areas to analyze during
simulation

3DCS Outputs
High-Low-Mean Sensitivity Analysis –
How much does the tolerance range affect
the product
GeoFactor Results –
How much does the part geometry
contribute to the product’s variation
Monte Carlo Simulation -
• Quality Metrics – Pp, Cp, Ppk, Cpk –
Methods of measuring variation in
production
• Key Contributors – Where is the
variation coming from
• Percent Out-of-Spec – How many builds
will fail to meet Specifications (non-
conformance)
• Range of Variation – How much variation
will be in the product (worst case)

3DCS as Part of PLM
Design
Simulation
ValidationRedesign
Manufacturing
Gap and Flush Objectives
Tooling Design
Optimize Tolerances GD&T and Assembly Sequence
Inspection Plan and Measurement AuthoringTest Solutions to Control Variation
Use Plant Data to Root Cause Issues
3DCS can be used throughout the product
lifecycle to support Dimensional Quality and PLM
Spec Study and Visualization
Monte Carlo Simulation
Sensitivity AnalysisWhat If Studies
Process Capability DB

3DCS in a Closed Loop System
Quality Intelligence
Engineering Through Production

3DCS FUNCTIONALITY
How does it work

Monte Carlo Analysis
Determine if the results of a measurement (specific area) will meet design objectives based on a
randomly varied tolerances across a series of simulated product builds.
The statistical output of the simulation is
displayed as a histogram showing the frequency
that the measurement is out of specifications
• Mean
• Standard Deviation
• Distribution
• Selectable Metrics (Pp, Cp, Ppk, Cpk etc…)

HLM Sensitivity
A "High-Low-Median", or HLM, Sensitivity Analysis provides information to make
improvements to the model.
HLM Sensitivity determines which tolerances have the largest contribution per
measurement.

GeoFactor
Similar to the High-Low-Median sensitivity analysis, GeoFactor examines the effect of each
tolerance on a given measurement. Unlike HLM sensitivity, which analyzes the range of a
tolerance, GeoFactor analysis examines the contribution of the tolerance based on geometry
effect.

USING 3DCS VARIATION ANALYST
Using 3DCS

Model Inputs
Part Geometry –
• GD&T and Tolerances
Assembly Sequence –
• Moves to assemble the parts
Measurements –
• Areas to analyze during
simulation

Spec Study & Visualization
Determine Gap and Build Objectives Before Engineering
(what is max and min tolerance objectives)
See How Variation Affects the Product’s Appearance (Perceived Quality)

Part Geometry
Nominal Part Geometry, Tolerances and GD&T
- Apply FTA (embedded GD&T)
- Point tolerances in 3DCS
- Feature tolerances in 3DCS
- Tooling tolerances (influence on design)

CATIA GD&T FTA Extraction and
Updating
• 3DCS models can be created faster and with less errors by extracting CATIA FTA
• Part and Assembly GD&T FTA is supported.
• No need to re-author data

Assembly Sequence
• The Assembly Sequence determines how
parts locate to one another and in what
order.
• In 3DCS, a "move" defines how a part is
located in space.
• Moves are added to the model to represent
each step in the build process.
A move reflects how the variation of the locating features is transmitted through to a product.

Measurements
• They aid in understanding the effects of 3D
tolerance stack ups.
• Measurements are used to determine how critical
dimensions in an assembly are affected by fixture
and part tolerances.
• Both points on a surface or the feature itself can be
used to define a measurement.
Measurements quantify the variation of the
desired output in the model.

Reporting
• Push Button Summary of Your Model Inputs and Outputs
• Automatically Created in Html or Excel

Additional Features
Color Mapping –
Use Color Mapping to quickly see trouble areas and communicate with managers and teams
Alias Display –
Change the names of your model features to make it easier to use, then when you are done, change them bac
Process Capability Database PCDB –
Connect your tolerances to a database of known processes or plant data
Embedded GD&T –
Use CAD based GD&T to quickly test designs and create models
Optimization –
Use wizards to optimize and rerun analyses to see the effect of
design changes
Specialized Tools

CATIA Rendering
• 3DCS allows users to visualize extreme Gap and Flush conditions and then
they can be visualized in real time with the Creo Rendering engine

3DCS ADD-ON MODULES
Expand your 3DCS software

FEA Compliant Modeler
 Determine the effect of flexible materials
during manufacturing processes
(aluminum, sheet metal, plastic)
 Apply forces to your parts and determine
the impact on overall variation
 Optimize processes like welding sequences,
riveting, bolting and tooling
 Incorporate Finite Element Analysis into
your Tolerance Analysis all in one software

Mechanical Modeler
 Incorporate kinematic and
mechanical moves into your model
 Use Joints and Constraints from
CAD or a built in library
 Use Degree of Freedom Counter to
determine constraints and validate
models

Assembly Constraint and Joint
Extraction
• 3DCS Mechanical models can be created faster and with less errors by extracting Creo
Assembly Constraints & Joints to create Mechanical Moves
• No Re-authoring data

AAO – Advanced Analyzer Optimizer
 Analyzers to quickly work with
large models and get a global view
of variation
 Optimizers to determine optimum
tolerances and designs
 Locator Sensitivity Analyzer to test
locator schemes and determine
the best options

Visualization Export
 Output fbx files to create seamless
workflows with high end
visualization tools (Deltagen,
VRED, Showcase)
 Turn your model into life like visual
images to showcase how the
actual product will appear with
given design specification

Inspection Planner
 Create inspection and
measurement places from your
CAD data
 Use within the CAD platform to
create reusable templates to
analyze plant and CAD data
 Use to bring plant data seamlessly
into CAD

WHO USES 3DCS?
Customer Stories

Companies Across the
Globe Use 3DCS
FIAT CHRYSLER
AUTOMOBILES
AIRBUS LG ELECTRONICS
GENERAL MOTORS
THE BOEING
COMPANY
PHILIPS
VOLKSWAGON EMBRAER MAGNA
BMW BOMBARDIER
SAMSUNG
ELECTRONICS
JAGUAR LAND
ROVER
LOCKHEED MARTIN WHIRLPOOL
AUTOLIV CESSNA TEXTRON MERITOR
VALEO FAURECIA PETERBILT
LENOVO TESLA GE
DAIMLER
DURA AUTOMOTIVE
SYSTEMS
KENWORTH
SONY GULFSTREAM TOYOTA
NISSAN ELECTROLUX LEXMARK
 Used by major OEM’s and
Suppliers across the world
 Industry standard
tolerance analysis tool in
the automotive and
aerospace industries
 More than 400 companies
worldwide use 3DCS

EXAMPLE APPLICATIONS

General Motors Results…
"Successful tolerance analysis
product execution played a major
role in our achievement of
high quality across our product
vehicle line. The Chevrolet Volt,
Chevrolet Silverado, Chevrolet
Malibu and Cadillac CTS were all
named Car/Truck of the Year
winners." Richard Korynski
Body Tolerance Analysis Manager-General
Motors

General Motors Results…
DCS…
The Ecotec program used 3DCS analysis. Moreso than other engine programs, although that
is quickly changing as more engineers are realizing its benefits. Use of 3DCS on all engine
programs has increased dramatically over the past two years.
3DCS was used in such studies as ...
Engine Combustion Variation (compression ratio)
Accessory Drive Belt System
Chain Drive and Valvetrain kinematics
Direct-Injection Fuel Injection System
Studies in Sensor Variation
Many packaging/clearance studies between components
Interface/Joint studies between components (fasteners and port alignments)
In-vehicle engine compartment packaging
Cordially,
E.M.
GM Powertrain Engine Design
L850 Tolerance Analysis Lead

Daimler Results…
 Tolerance Planning is the Way to Improve Product Quality
 3D Tolerance Simulation is a suitable Tool to evaluate and improve Tolerance Concept
 We took Benefit from using 3DCS in a first Car Project
 There is still Potential in reducing the Efforts & Costs for the Modeling itself
 Therefore we will especially work with 3DCS to further enhance
- Performance & Robustness
- CATIA V5 Integration
Dr. Alexander Layer & Hansjörg Ströhle
Daimler AG

Chrysler Results
“New Metrology Culture Improving Chrysler Quality”
SME Magazine
“Five years ago, our fit and finish was below average,” said Dr. Raj Kawlra, director
of dimensional strategy and management of Chrysler Group (Auburn Hills, MI).
“To be the future world-leaders, we knew that we had to focus on all aspects of
quality … vehicles that look good, feel good, sound good, and are reliable.”
Link to article: http://www.sme.org/MEMagazine/Article.aspx?id=77027

LG Case Study
DO NOT DISTRIBUTE

Embraer
The main purpose of the tolerance analysis was to assure and improve final product quality. The analysis results justified the need of
design changes to accommodate dimensional variation. The amount of predicted variation identified the need to change gap and seal
specifications as well as helped optimize hinge designs to guarantee no pre-stress and increased product life. The software also
supported the definition of pre-manufactured shims now used in production. 3DCS also helped Embraer find possibilities to use
“coordinated assembly” minimizing tooling which lowered production costs with guaranteed product quality. Additionally, tolerance
analysis and simulation techniques motivated and supported process development strategies to guarantee process variation
compensation on composite tooling design.
Daniel C. da Silva, Embraer Tolerance Analysis Team Leader “The 3DCS technology brought our commitment to product quality and safety by
design to an even higher level. The tool not only can quantify our technical decisions but truly helps our IPD
teams to numerically and visually discuss spatial dimensional variations and its management early in the design phase. These facts, together with
an integrated Catia V5 environment, intensive technical training and the DCS top support and development service were the key to our success in
this custom development for JetBlue, one of our key EMBRAER 190 customers.”
“The Live TV Radome (radar dome) is used to protect the
antenna, which sits on top of the E190 fuselage. The
structural Radome assembly consists of about 50 parts with
over 150 key tolerance specifications. It was Embraer’s first
production usage of 3DCS … software on a totally new
development project.”
Live TV Radom Variation Study

Case Study: Embraer
Throughout the process, the mantra
was ‘more for less’…
The GD&T we used to develop this final interior has
enabled the best craftsmanship and cabin experience in
the industry
- Jay Beever, vice president of marketing and interior design at Embraer
“
”
“ ”
Legacy 450 and 500
Business Jet Interiors international April 2014

Legacy 450 and 500 Interior
Parker, Selwyn. "Legacy 450 and 500." Business Jet Interiors International
April (2014): 60-66. Business Jet Interiors International. UKIP Media & Events Ltd, Apr. 2014. Web.
“In this a key element was a process known as geometric dimensioning and tolerancing
(GD&T) that, broadly speaking, tells manufacturing staff the exact degree of precision
required on each controlled feature of the assembly” (Parker 2014, p. 62).
“…the sideledge lids and storage bins
are so precisely engineered that they
operate almost like jewelry boxes.”
Business Jet Interiors International, pg 63

Boeing 8A Poseidon
• Radar attachment points
• Designed in parallel with refit
• Given two points in space to design to.
• Final product ‘clicked’ into place.
http://www.boeing.com/boeing/defense-space/military/p8a/

Case Study: AN/APY-10 Radar
• 2 Initial Locators Given
• Design Composed Parallel with Aircraft
• Variation analysis to determine necessary
characteristics
Parallel Design and Testing
Locator Points for Assembly
http://www.raytheon.com/capabilities/products/apy10/

Airbus
Issue: Shimming at final assembly increasing weight and decreasing fuel efficiency.
Challenge: Determine key characteristics at attachment points and reduce assembly
variation.
Solution: Dimensional Analysis with 3DCS assisted in improving build strategy and
controlling variation at primary connection points.
Results: Total shimming reduced by
40% in aircraft assembly.
Analysis to Reduce Aircraft Assembly Shimming

Airbus Feedback Loops

Case Study: ITER TOKAMAK

Toroidal Field Coils
Self Supporting Electro Magnets
Fit Like ‘Orange’ Slices
Keystone Piece Imperative
Fusion Reactor

Consumer Electronics
Laptop Internal Component
Variation Analysis
Issue: Variation of Internal components of laptop causing assembly build issues
– hard drive, mother board, ram chips, etc… - Limited space inside of Laptop case
creates very little room for variation. Changes in components from manufacturing
variation were causing cases where the components did not all fit inside the case.
Solution: Simulating the assembly sequence with variation taken into account provided
new insight into the source of the variation and primary trouble areas.
Results: With basic design changes to the placement of the components, the current
amount of variation was accounted for, requiring very little adjustment in tolerances.

Consumer Electronics
Issue: Variation in lens connections causing build issues.
Solution: Simulation in 3CS of assembly determined
contributor and true cause of variation.
Results: Basic design change and simulation validation
produced a reduction in overall assembly variation,
greatly reducing the chance of assembly build failures.
Demonstration Model Only
Camera Fit Analysis

Transportation
Snowmobile Shock Analysis
Issue: Shock was freezing up when
placed under larger forces, such as a
jump or heavy landing.
Solution: Using 3DCS Mechanical, the
shock was simulated with variation from
manufacturing as well as assembly
processes and through a large range of
different forces.
Results: At higher levels of force, the shock was seizing from a variation build up
connecting with the spring system. This was unforeseen as it stemmed more from
process than part tolerancing. A minor adjustment to the process negated the
problem, using simulation to validate.

Results: Choosing the best option, for manufacture and
assemble-ability, as well as appearance, the customer was
able to determine a design change to the hole/pin attachment
at the rear of the drawer that allowed for enough float to keep
tolerances from being too tight, while not sacrificing the
drawers function and appearance.
Medical Device
Drawer fit and function
Medical Defibrillator Drawer Analysis
Issue: Front drawer of the device did not fit properly during assembly.
Solution: 3DCS was used to simulate the variation and perform iterative analyses on possible
solutions. These were compared, using Spec Studies to determine the appearance of each
solution.

Home Goods
Demo Model Only
Customer Model Not Shown
Washer Dryer Spec Study and High End Visualization
Issue: Customer was concerned that the current design, when built, may have offset
components such as doors, buttons or control nobs at extreme tolerance situations (ie.
One side at maximum condition, and one side at minimum condition).
Solution: High End Visualization was added to various scenarios using design tolerances
to show possible extremes.
Results: Customer modified
some tolerances in order to
reduce the chance of certain
scenarios while leaving others
the same due to lack of change
to product appearance.

Ship Building
Crane Internal Mechanisms
Issue: Mechanical components of the crane
Inside the ship are having functional issues.
Solution: 3DCS Mechanical was used to analyze the
assembly and through its entire range of motion,
determining possibility of out of spec conditions.
Results: Adjustments from general tolerances to
specific ones for various components reduced the
possibility of out of spec conditions.

Heavy Machinery
Boxcutter Assembly Analysis
Issue: Optimization of tolerances for less
expensive manufacturing while retaining full
functionality.
Solution: AAO, Advanced Analyzer and
Optimizer, was used to quickly determine key
tolerances and critical areas.
Results: Using AAO, tolerances and features that were not key
to quality had their tolerances opened up, while key areas were
tightened to improve assemble-ability. This overall reduction in
manufacturing costs had a positive outcome on overall product
cost.

CATIA Integrated Tolerance Analysis - 3DCS for CATIA V5

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