Exploring Virtual Geometry Assurance for the Nominal Buck Verification Process at Polestar
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Examensarbete för masterexamen
Master's Thesis
Master's Thesis
Modellbyggare
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Sammanfattning
This thesis investigates the feasibility of digitalizing the nominal buck verification
process at Polestar using virtual geometry assurance software such as RD&T. The
nominal buck, a physical aluminum structure representing the ideal chassis geometry,
is currently employed in Polestar’s verification process to evaluate the fit and alignment
of interior and exterior vehicle components. Although the process is reliable
with a high accuracy when it comes to asserting the geometric state of a part, the
process is costly, time-consuming, and environmentally demanding. The objective
of this study is to assess whether a virtual alternative can replace or complement the
physical verification approach to improve efficiency, accuracy, sustainability, costeffectiveness
and flexibility.
Through a combination of literature reviews, industry interviews, and a detailed
case study, the project explores the capabilities of RD&T for simulating geometric
variation and part assembly. The digital method involves 3D scanning of physical
parts, creating virtual fixtures, and applying statistical variation analyses to predict
assembly behavior and compliance with tolerances. The research also includes a
comparative analysis between the physical and digital approaches, highlighting advantages
such as reduced lead times, lower material consumption, increased process
flexibility, and enhanced data traceability.
The results suggest that a virtual verification process using RD&T can significantly
improve the robustness and efficiency of the geometry assurance processes
at Polestar, with additional sustainability benefits including waste reduction and
streamlined global collaboration. However, challenges such as software limitations,
implementation complexity, and required changes in workflow and skill sets must
be addressed. This thesis contributes to the advancement of digital manufacturing
practices and supports Polestar’s strategic sustainability and innovation goals