3DCS Advanced Tolerance Analysis - 5 Additional Analyzers and Optimizers

Dimensional Control Systems | 2017 All Rights Reserved
3DCS Advanced Analyzer and
Optimizer Add-on
Use advanced analyzers to view work with large models
and optimizers to reduce your work load

What is AAO?
5 Tools in One
1.Advanced Analyzer
2.Critical Tolerance Identifier
3.Tolerance Optimizer
4.Cost Optimizer
5.Locator Sensitivity Analyzer

You have a large model with a lot of measurements or tolerances
You want to know which part in the assembly is causing the most variation
You want to optimize your tolerances quickly
You want to know which measurements should be measured in production
You want to check your locators or test different locating strategies
You want to do What If studies on different tolerances across the model
Why Use AAO?

ADVANCED ANALYZERS
Get a system level view of your model

Where is My Product Most Sensitive?
Advanced Analyzer Matrix
• Based on GeoFactor Analysis
• Six Methods of Combining Contributors

Advanced Analyzer Matrix
• Quickly identifies where design is sensitive to variation
• Enhanced GeoFactor results
• Change individual tolerance ranges for instant results
• Show GeoFactor or Percentage Contribution
• Global color scaling based on adjustable sliders

What If Studies
• Change tolerances within the matrix
• Receive instant results
• Test different What If scenarios
• Only update the model when you
want to
• Customize color code for pass/fail

Critical Part Identifier
• Show contributors per part
– All contributors and all features on a part
– Which part is giving me the highest contribution
overall to my system (product) variation

GeoFactor Inside AAO
• The GeoFactor Table is accessible from the matrix

GeoFactor Mean Shift Table
Ranks affect of Tolerance Offsets

Geofactor Mean Shift Table
• Give users an idea of where mean shifts are coming from.
• Only analyzes off sets placed in tolerances.
• Many other contributors not included, so does not get used too
much.
• Value: Quickly comprehend mean shifts in your system
• We focus on analyzing variation, mean shift is just as important.
• See shifted tolerances and how it affects your measurements.
• In production, Mean Shift is what you are looking for. Is the sign of
an issue in manufacturing.

Which Tolerance Contributes the Most
Variation
Critical Tolerance Identifier

GeoFactor Alone
• 1 measurement at a time
• Small scale
• Cannot set spec limits
• Does not show mean shift
AAO (includes GeoFactor Function)
• All measurements in matrix
• Large scale
• Set spec limits and make changes
• Mean Shift analyzer
Identify the greatest contributing tolerance globally

• Pp*: weighted by spec limits, no mean shift
• Ppk*: weighted by spec limits and mean shift
• Out%: weighted by out-of-spec results
• Ave%: average % contribution per measurement
*Process Performance or Process Performance Index
Quantifies the effect of each tolerance (or hole-pin float) on
the measures simultaneously and globally

Tolerance Contributing the Most
Variation

OPTIMIZERS
Increase quality while decreasing cost

Increase Tolerances to Save Money
(6tk)2
Costk
(6tkmin)2
(6tkmax)2
Costkmin
Costkmax
cck = (Costkmax - Costkmin) /
[(6tkmax)2
- (6tkmin)2
]
Tolerance Optimizer

Tolerance Optimizer: Cost
• Combination of tolerances that can meet set goals.
• Set adjustment amounts to limit tolerance changes
• The software adjusts tolerances (goal is to open up, not
tighten, to reduce costs overall) in order to meet given
goal values.
• Initial goals are taken from the spec limit
• Weighed value – max will be 0, and min tol will be
given ‘cost’

Tolerance Optimizer: Cost
Achieve desired quality at minimum cost
Goal Value (spec lim)
Max, Min, Lock, Cost
Opt Meas
Opt Tol
Total Current Cost, Total
Optimized (Minimum) Cost
Input
per Measure
per Tolerance
Optimizer
Output
*Assumption: larger tolerance = less cost

Optimizer Assumptions
Measures
• Goal Value: check all spec limits, default is fine
Tolerances
• MaxTol/MinTol
– Profile, MinTol = 1.0mm
– Position, MinTol = 0.5mm
• Locking
– Tooling (no ability to change)
– Size (low influence on model)
• Cost
– Profile tolerance costs 20% of Position tolerance
– All other tolerances equal

Determine Optimum Tolerances
With Defaults
With Assumptions
After Max/MinTol Adjustments
based on CTI results

Update the Model Only When You
Want To
Manually enter tolerances according to results
Increases Cost
Decreases Cost
Remains Constant
The Update Model Tolerances button pushes OptTols back to the model
OR

Tolerance Quality Optimizer
Achieve best possible quality at a defined cost
Goal Value, Weight
Max, Min, Lock, Cost
Total Available Budget
Opt Meas
Opt Tol
Total Current Cost, Total Optimized
(Minimum) Cost, Optimized Quality
Value
Input
per Measure
per Tolerance
Optimizer
Output
*Assumption: Weight and Cost are relative values

Tolerance Optimizer Quality

Quality Optimization Assumptions
Measures
• Goal Value: check all spec limits, default is fine
• Weight: set unimportant measures to zero
Tolerances
• MaxTol/MinTol
– Profile, MinTol = 1.0mm
– Position, MinTol = 0.5mm
• Locking
– Tooling (no ability to change)
– Size (low influence on model)
• Cost
– Profile tolerance costs 20% of Position tolerance
– All other tolerances equal
Other
Total Available Budget: estimated cost (assume
unlimited to see best quality)

Determine Optimum Quality
With an “unlimited” Budget, best achievable quality is -0.412 @ $8276.25
Assume an Available Budget of $5000, quality is -0.586
After Max/MinTol Adjustments with $5000 Budget, quality is -0.436

Push Button Update to Model
The Update Model Tolerances button pushes OptTols back to the model
Manually enter tolerances according to results
Increases Cost
Decreases Cost
Remains Constant
OR

LOCATOR SENSITIVITY ANALYZER
Find which move is causing the most variation (Assembly Analysis)

Analyze the Sensitivity of Locating
Features
Does the variation get better or worse if I make my locator tighter?
Which Locating Method provides the least amount of added variation to my product?
Which move is most critical to my overall assembly?
Model multiple location methods and test each one
Analyze in advance, what if we modify our locators? Spread them out, move an individual
locator?

Test Fixtures for Variation
Three different locating methods
Representing possible tooling or fixtures
Simulating a tool,
understand the multiple
different geometric
effects based on changing
my locators

Calculate the Variation
LSA moves all the target positions and points independently based on locator tolerances (set
here at 0.50 and then checks the entire geometry of the part for its maximum variation

Color Mapping
Isolate and view specific sources of variation
• Focus on one part or the entire assembly
• View geometric effects based on changing location

Compare
Visually see the
variation between
different locator
strategies

Advanced Analysis Tool
Analyzing the sensitivity of the locating features
Focus on one part:
View geometric effects based on changing location

Which Locator or Direction is Most
Sensitive
• LSA can be set to one direction of variation (X,
Y or Z, or all three)
• If set to XYZ, it will show only one number, the
Root Sum Squared of X, Y and Z variation
combined.

3DCS Advanced Tolerance Analysis - 5 Additional Analyzers and Optimizers

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