Non-Nominal Physical Representation of Early Design Concepts in the Automotive Industry

Examensarbete för masterexamen

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Type: Examensarbete för masterexamen
Master Thesis
Title: Non-Nominal Physical Representation of Early Design Concepts in the Automotive Industry
Authors: Wagersten, Ola
Nilsson, Staffan
Abstract: This master thesis was carried out in cooperation between Volvo Car Corporation (VCC) and the department of Product and Production Development at Chalmers University of Technology. The background of the thesis is that in today’s development process all mock-ups used for evaluation of a car’s exterior are imprecise in adjustment, complicated to set up and are not controlled by statistical simulations. In the near future VCC is going to implement a new method regarding physical mock-ups in early design phase. The object of the thesis was to find a solution to how to automatically visualize non-nominal representations in a physical mock-up. A prerequisite was that the solution had to be compatible with the new method at VCC. Based on the information from an investigation of the new method, a robot was designed to be used mainly by the Product Design department at VCC. The purpose for the robot is to serve as a means for the evaluators to judge outturn of the industrial design including the impact of tolerances. The function of the robot is to position a visual part of the exterior in six degrees of freedom, for example a rear lamp. The positioning data that serves as input to the robot comes from a simulation in the software Robust Design & Tolerancing (RD&T). The robot requires input data that is in another form than what is exported from RD&T. To translate the data a program was developed to perform necessary calculations. The six degrees of freedom are translations along the X, Y and Z axes and rotations around the same axes. To realize the movement the robot is put together by six main components. In the bottom there is a rotating table to provide rotation around Z axis. On top of this there are two linear motor stages to provide translation along X and Y axes. Three linear actuators mounted in a triangle on top of the linear motor stages accomplish the remaining three degrees of freedom. To enable quick mounting and demounting of the robot onto the underlying framework an adapter was developed. An adapter was also developed for the mounting of the part onto the robot. All the main objectives of the thesis were achieved. To realize and implement this concept further investigation and development has to be done by VCC. It has to be assured that it is possible to assemble the robot with enough precision.
Keywords: Konstruktionsteknik;Övrig industriell teknik och ekonomi;Produktion;Construction engineering;Other industrial engineering and economics;Production
Issue Date: 2004
Publisher: Chalmers tekniska högskola / Extern
Chalmers University of Technology / External
Series/Report no.: Examensarbete / Institutionen för produkt- och produktionsutveckling, Chalmers tekniska högskola : 62
Collection:Examensarbeten för masterexamen // Master Theses

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