It is not only in the motor industry that market leaders outstrip their competitors by introducing new products quickly, in top quality and at the lowest-possible prices. As a result, efficient, high-performance product creation processes are increasingly seen as the key to boosting a corporation's competitiveness. Novel manufacturing technologies like Rapid Prototyping and Rapid Tooling render important contributions in this respect; they have not been fully integrated in the digital environment to date, however. When applied in production, Rapid Prototyping and Rapid Tooling provide enormous potential in the production of both technical prototypes and small series. The range of applications for components made by means of Rapid Tooling production tools is growing. In this field, RT competes with conventional manufacturing technologies like HSC (high speed cutting). The goal is to achieve batch sizes of 10,000 injection-molded parts with RT tools. A precondition for the successful application of Rapid Technologies in production is, however, the assurance of component quality at every stage of product creation. To reach this objective, DaimlerChrysler develops networked quality loops. A consistent database is used here, storing not only the target geometry of the finished components but also the corresponding geometry information for every manufacturing step. The quality features are consistently defined for all manufacturing steps. The feature information used forms the basis for automatically deriving quality features. To this end, target values and the necessary tolerance information from the feature description are transferred to the relevant quality features. With two-dimensional measuring technology, a component is recorded very quickly indeed. By using a simple positioning robot in addition, measurements can be automated to a major extent. In these measurements, precision levels up to 0.04 mm are achieved. With the help of a software (QSpect) specially developed for the processing of large data volumes, the points recorded can be used for a target/actual comparison with a target description. The results can be directly implemented in the next process step; this results in small quality loops in which faults in the production process are detected at an early stage and higher rectification costs avoided.
Digital quality loops in rapid manufacturing processes
Digitale Qualitätsregelkreise in schnellen Fertigungsprozessen
Progress in Virtual Manufacturing Systems, CIRP International Seminar on Manufacturing Systems, 36 ; 27-31
2003
5 Seiten, 11 Bilder, 4 Quellen
Conference paper
English
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