1-DCS

Presentation

Dimensional Control Systems Inc 2009

1Dcs Objectives

What are Linear Tolerance Stacks? Advantages of1DCS Who benefits from1DCS Stack Studies? Methods for Calculating Variation using 1DCS. 1DCS Functions. Creating a1DCS Model.

Dimensional Control Systems Inc 2009

1Dcs...

A statistical software used in a linear direction to mathematically calculate or simulate assembly variation. Quick and effective way to help determine assembly processes early in the design phase. Allows user to graphically represent each assembly sequence.
Dimensional Control Systems Inc 2009

Advantages of1dcs
Quick
Easy to use. Provides results in short period of time.

Working Tool
Iterations can be adjusted during meeting to provide instant feedback as to impact of Design or manufacturing proposals. Excellent brainstorming tool. Provides concept ideas with direction and impact. Logic Trees

Tolerance Budgeting
Used early to determine amount of tolerance that can be given to major sub assemblies. Determine reachable Tolerance Objectives for complete vehicle.
Dimensional Control Systems Inc 2009

Who Benefits from1dcs Studies?

Product/Design Engineering
Analyze dimensional relationships within an assembly during design. Objectively understand impact of product/tolerance change requests. Incorporate Manufacturing and Stamping/Fabrication concerns to make designs more robust.

Stamping/Fabrication
Reduce the cost of piece parts by using maximum allowable tolerances to meet Design Objectives. Incorporates Design Objectives and Manufacturing process to establish piece part tolerances.

Manufacturing
Provide a clear assembly process throughout all engineering communities. Identify assembly problems during the concept stage, to avoid costly design, part and tooling rework changes. Provides for a shorter lead time to full scale production.
Dimensional Control Systems Inc 2009

1Dcs - Analysis Calculations

Worst Case or Straight Stack (Allocate or Capability) Mathematical Calculation: A + B + C + D = Stack Result Sum of all tolerances RSS - Root Sum Squares Method (Allocate or Capability) Mathematical Calculation: (A)2 + (B)2 + (C)2 + (D)2 = Stack Result Monte-Carlo Simulation Method This method uses a random number generator to select a tolerance within the tolerance range and add this to other tolerances in the linear system that have also been randomly chosen. Mathematical Calculation: Random of sample A + Random of Sample B + Random of sample C + Random of sample D = Sample Result
Dimensional Control Systems Inc 2009

1Dcs - Analysis Methods

Allocation - Roll Down Method, for use when you desire to
allocate more of the total allowed variation to certain features. Plus/Minus
The Objective (end result) that you are trying to achieve The mathematical factor assigned to the amount of tolerance is to be distributed to the node. For the purposes of the following examples there are three nodes, A, B & C. The amount of tolerance being Allocated Down (Objective) to these nodes is +/-0.75. Ex 1. The Weight factor for each node is set at 1. Meaning that each node will receive the same amount of the Allocated tolerance. Under this scenario each node will have allocated or distributed +/-0.25 to it. Ex 2. If the Weight of tolerance A is set at 2, while B & C Weight remains at 1, then the tolerance will be distribution based off of a Weight distribution factor of 4. In other words node A will receive 2/4 of the allocated tolerance, while B & C will each receive 1/4. Part A will receive +/-0.375 and B & C will each have +/-0.1875 distributed to them.

Weight

Value locked
Allows the user to input a tolerance and Allocate downwards without changing the specified tolerance. Ex 3. The operator places a tolerance of +/-0.5 in for tolerance node A, and checks the Value Locked box. In this case, +/-0.5 will be first allocated to tolerance A. Then the remaining balance, +/-0.25 (0.75-0.50), of the Objective tolerance will be distributed to nodes B & C, each receiving +/-0.125. This is assuming that B&C both have a Weight factor of 1.
Dimensional Control Systems Inc 2009

1Dcs - Analysis Methods

Capability - Roll Up Method, , for use
when you desire to understand how the accumulation of feature tolerance affect the assembly variation.

Plus/Minus
The Detail level part tolerances that are achievable.

Geom (Geometry) Factor

In a linear stack values are calculated in either the X,Y or Z coordinate direction. Since part design is not always true to grid coordinate, part flanges and features can have a angle or degree relative to the coordinate system. The Geom Factor feature will take into effect those degrees and apply a geometry effect during the calculation. Ex. A study being done in the X linear direction has a mating flange that is at a 45 Angle. By using the sine Value of 45 =.707 we can input the impact of that flange into our calculation.

See next page for a description.

Dimensional Control Systems Inc 2009

Geo Factor

Part

45 Y

The Sine of 45 is equal to .707

Explanation: The part mating flange is at a 45 degree angle to the X axis. Therefore in the study in the X direction we add in the given tolerance for the flange and account for the angle in the study by adding in the geometric effect.
Dimensional Control Systems Inc 2009

1Dcs

Distribution Types

Normal: This distribution is used for tolerances that are distributed according to a standard bell-shaped curve. Uniform: A "flat" curve where every tolerance value in the defined tolerance range has equal probability of occurrence. Triangle: The curve reflects the shape of a triangle with a peak in the center. Min-Max: Every tolerance value in the defined tolerance range has the same probability of occurrence only with the minimum and maximum values. Weibull Left: A curve where the majority of parts fall within the positive or right side of nominal. Weibull Right: A curve where the majority of parts fall within the negative or left side of nominal. Open Up: The majority of tolerances are closer to the upper and lower limits, however some can fall at or close to nominal. Open Down: The opposite of Open Up - a hybrid between a Normal and Uniform distribution. User Defined: This curve type is the actual data provided in a file. Typically this uses the CMM results and is loaded by the User. Step: Every tolerance value in the defined tolerance range increments in small steps of variation similar to a uniform curve. Constant: This distribution assigns the same value to the tolerance every time the tolerance is used.

Dimensional Control Systems Inc 2009

Steps to1Dcs Modeling

1. 2. 3. 4. 5. Determine the Objective or Requirement. Identify the assembly process. Input the detail part tolerances (Capability Up) and the final build objective (Allocate Down). Input Manufacturing Tool information. Perform the calculation.

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1Dcs Icon Definition

Monte Carlo Simulation Capability Up Allocate Down Add Node Straight Stack Simulation Root Sum Squared Delete Node Auto Scale Redraw

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1Dcs Node Definition

Node Title Sigma Definition (Range) Node Description Allocate (Down) Range, +/- Tolerances Weight Capability (Up) Range, +/- Tolerances Geometric Factor Simulation Distribution Type Resulting Simulation Tolerance

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Objective Requirement
Step 1: Determine Objective

Dimensional Control Systems Inc 2009

1dcs - Editing a Node

A description detailing specific information for each node Sigma Level can be chosen from 3 Sigma through 10 Sigma

The desired Result or Objective to be Allocated down and distributed between all of the nodes in the assembly tree.

Select if identifying a fixture or assembly aid tolerance.

Weight allocates priority to current

feature for allocation of tolerances.

Individual tolerance used to solve upward.

Value Locked locks the current tolerance during allocation studies.

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1DCS Objective Box

After you have entered in the information and close out the edit node screen you should now have a node that looks like this. The red circle show the tolerance that you have just added.
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Assembly Information
Step 2: Determine the Assembly Process.

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1dcs Assembly Tree

Add a Node button

The highlighted Node was created in Step 1. Each click of the Add a Node button will add a lower level Node under the highlighted node. In this case three clicks produced three nodes under the main objective node. As many nodes and tiers of nodes can be defined in the assembly. At this point you are developing the assembly sequence. Tolerance definition will be described in the next step.
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GD&T Design Information

Step 3: Input Detail Part Tolerances

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1dcs Asm with GD&T

Objective

Tier 1

Tier 2

By clicking or highlighting the Tier 1 part/assembly, the user can add as many tier 2, 3, etc parts, subassemblies, tolerances as needed to define the process.
Dimensional Control Systems Inc 2009

1dcs and GD&T

By double clicking on the desired node the operator can enter each tolerance similar to that of step 1.

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Manufacturing Information
Step 4: Input Manufacturing Tool Tolerances

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1dcs with Manufacturing

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1dcs with Manufacturing

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1Dcs - Database
Displayed in Node

Capability Allocation Meanshift Capability calculation Statistical distribution for each node Plus/Minus Sigma value used to calculate each tolerance

Trigometric influence of tolerance in a linear direction

Allows node to allocate larger value.

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Perform Calculation

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Objective Results
Capability Up
1.75
With all attainable tolerances the objective will not be met.

Allocate Down
Tolerances needed to met Objective

0.41
Right & Left Floor Flanges

0.32
Tunnel Flanges

Dimensional Control Systems Inc 2009

1DCS - HISTOGRAM
This is the Total number of simulations run. This the Minimum and Maximum Results of the simulation. This indicates the acceptable design limits. This indicates the % of builds out of specifications. These results are Within Specification. Lower Design Limit Upper Design Limit

These results are Out of Specification.

This value represents the shift of the Mean.

This value represents +3 Standard Deviations.