The future competitive situation in the automotive industry and the increasing market demands will inevitably lead to higher complexity in product development, production planning and pre-series. Longer lifecycles of assembly systems based on highly flexible production cells with a rising number of integrated processes call for new challenges, especially for production engineering. One key challenge for gaining important time and cost potentials in production engineering projects is an early virtual validation during the pre-series. Under the premise to replace physical mock-ups by digital mock-ups, we will present requirements and solutions of a virtual validation focused on manual assembly of high-voltage components in the automotive industry. We want to integrate the electric drive used for electric and hybrid vehicles into the computer aided design based virtual validation process. In this paper a product and process validation methodology for prototype electric drive, using a virtual human model has been presented. First, an analytical dismantling of a physical model has been carried out to identify the manufacturing steps. With this the identified manufacturing steps are then assigned to an existing production scheme. Second, a concept for a virtual validation of the assembly of electric drives has been developed. For this, relevant aspects were identified by conducting an expert survey. For two selected process-steps, i.e. packaging of electrical sheets and insertion of magnets, a virtual validation concept is developed. This concept enables us to detect possible sources of errors and hazards at an early stage, allowing installing preventive measures. Third, in addition to the product-related virtual validation, the modeling and simulation-based design of a manual workstation is performed with DELMIA V5 to integrate the virtual human model to perform further ergonomic analysis within the virtual validation.
Methodical integration of assembly specific influences concerning high-voltage components into the virtual validation process
2012
8 Seiten, 7 Bilder, 22 Quellen
Conference paper
English
Validierung , Elektroantrieb , Produktentwurf , CAD (Computer Aided Design) , Prozessintegration , integrierter Prozessor , Automobilindustrie , Lebenszyklus , Montagesystem , Aufbausystem , flexible Fertigungszelle , digitales Mock-Up , Elektrofahrzeug , Hochspannung , Betriebstechnik , ergonomische Analyse , vorbeugende Maßnahme , Elektroblech
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