Polyworks Conference USA 2017, Novi, MI Improving ... · PDF fileIMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS MAIN PRESENTATION SUMMARY • Example 1: Use of GD&T tool

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


INTRODUCTION

Associate’s degree in

Aerospace Design

engineering (3 years)

Bachelor’s degree in

Mechanical engineering

(4+ years)

NO METROLOGY OR GD&T TRAINING


INTRODUCTION


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


INTRODUCTION

“To accelerate the world’s

transition to sustainable

transportation.”

Tesla’s Mission


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.


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


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


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


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.


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



EXAMPLE 1:

USE OF GD&T TOOL IN POLYWORKS

TO BETTER REFLECT 2D DRAWING

REQUIREMENT



Example 1



Example 1

1

2

3

4



Example 1

56

7

8

9



Example 1

1



Example 1

1 Datum A



Example 1

1 Datum A



Example 1

2



Example 1

2 Datum A

Surface

Profile



Example 1

3



Example 1

3 Datum B

Pattern of 3

Cylinders



Example 1

4



Example 1

4 Surface

profile all

around



Example 1

5



Example 1

5 Datum D



Example 1

6



Example 1

6 Datum E



Example 1

6 Datum E



Example 1

7



Example 1

7 Datum F



Example 1

8



Example 1

8 Circle 1

True

Position



Example 1

9



Example 1

9 Plane 1

with

Unilateral

Surface

Profile



EXAMPLE 2:

FEATURE REFERENCE TARGET VS

DATUM REFERENCE FRAME

ALIGNMENT



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.



Feature Reference Target versus Datum Reference Frame Alignment

GD&T Engineering requirement



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.




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.




The Body X-Y-Z

coordinate system

are not squared with

the alignment

direction defined by

each reference

target.




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.




View Normal to ZX Plane

View normal to Datum A



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.




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




View Normal to ZX Plane

View normal to Datum A




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.



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.

Documents

Polyworks Conference USA 2017, Novi, MI Improving ... · PDF fileIMPROVE DIMENSIONAL ANALYSIS USING GD&T WITHIN POLYWORKS MAIN PRESENTATION SUMMARY • Example 1: Use of GD&T tool