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Developing Custom Modeling Tools at GM with embedded Validation

James A. BullardGeneral Motors

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ABSTRACT

Automotive Design and Engineering at GM are constantly looking for technology to automate processes. This search for automation technology provides many unique requirements that drive the development of custom CAD Modeling tools. To make sure that the return on the investment is achieved GM is embedding validation tools to assure quality of Math as well as quality of process execution. This paper will describe projects that have developed custom Modeling Templates with Validation “agents” built in. These validation agents will not only validate quality of the math but also the overall process execution or usage of the templates.

General Motors Validation Facts

Check-Mate as globally agreed upon CAD validation tool

Successfully implemented Check-Mate at all Engineering Centers Globally

Enforced 53 Check-Mate Checkers as part of GM workflow

Check-Mate used as CAD Data Assessment Tool

More than 200,000 NX parts assessed weekly using check-mate batch mode

Significant improvement in Math data quality

Purpose

Overview of GM Development Project in 2008 of Math Data Quality Validation in Product Templates

Articulate the importance of Math Data Quality and particularly as it applies to Re-use geometry tools as Corporate Assets

Describe a Validation framework for Templates that incorporates Requirements Driven Design Validation (RDDV) embedded in Product Templates

Highlight Challenges to further develop this strategy and direction

Embedded Validation Tool for Global Template Based Component Project

Objectives Assess completed templates

Develop Bill of Requirements/Validation rule set

Define framework/architecture for template validation and enforcement strategy (must be flexible in order to comprehend future requirements)

Develop 1 Profile and 10 Requirements Driven Design Validation (RDDV) checks for each template

Develop requirements list for embedded RDDV checkers for new templates

2008 Timeline

OrganizeBusiness

AndIS&S Teams

Plan & Definecomplete

BusinessRequirements

Close

Feb Mar JunJan Apr May Jul Aug Sep Oct Nov Dec

Projectcomplete

UAT

Math Data Cycle

CheckMate Profiles and Checks need to address all areas of the cycle

Math Data Producers Math Data Consumers Re-Use of Math Data

CheckMate Profiles and Checks need to be aligned with the requirements of these areas

CheckMate Profiles and Checks also used to improve Math Capability (CAD Methods)

ProducerDesigners &

DE’s

ConsumerDownstream

Customer

Re-UseCertifiedQualityMath

Profiles & checksNeed to target all

Perspectives

Math Cycle

Templates turn Data Producers

into Data Consumers

Templates turn Data Producers

into Data Consumers

DesignFunctionChecksFabrication

ProcessChecks

ModelingBest

Practice Checks

Geometry IntegrityChecks

File OrganizationChecks

Hierarchy of Math Quality

Scope

Val

ue

Check-Mate Capability

Validated and Managed Templated Math Data is an Investment

Re-use is a high priority in any corporate strategy

Validated Templates come with pre-loaded Data Consumer value

CAE data – material properties, mid-surface features, etc…

CAM data – holes, drills, etc …

PMI – embedded tolerances, VSA modeling data, etc…

Templates are investments that can pay dividends when validated and managed

Validation Framework – Project Prototype Targeted Template Part

Exhaust ManifoldGM Powertrain

Validation Framework - Dimensions of Validation

Validation Of Templates

Math Data Quality (MDQ)

Component Engineering Requirements

Fabrication Requirements

Systems Of Templates

Managed Interfaces

System Level Geometry Requirements

Dimensions of Validation

Siemens Toolset

CheckMate RDDV Core NX

Math Quality

Engineering Requirements

Fabrication Requirements

System Requirements

Toolsets need to work together and “know” about each otherThey should be able to communicate to each other

Validation Framework – Prototype Validation Requirements

Dimensions of Validation for Prototype Math Data Quality

File Organization – GQS Profile (CM) Vehicle Partition code (VPPS) Examine Geometry

Component Engineering Requirements Sketch Dimensions – Port Opening (RDDV) Minimum Wall Thickness (RDDV) Minimum Blend Radii (RDDV)

Fabrication Requirements Embedded tolerances

System Requirements Managed interfaces Port Surface Datum Planes (CM) Port Datum Axis (CM)

Template Validation Framework

The Framework should allow for dynamic/flexible profile configuration to support multiple validation profiles or “levels” based on template purpose & discipline (ie., single component vs. sub assembly, BIW vs. PT)

Release Part Rqmts

Engineering Rqmts

Test Rqmts

Mfg Process Rqmts

System Rqmts

Org Rqmts

Validation Framework – Prototype Requirements Document

Requirements Validation

Future direction to link to Teamcenter System Engineering (TcSE)

Prototype using Excel Spreadsheet

Future Challenges as Strategy Evolves

Template Structures

Many ways to organize template structure which drive too much variability into structure and thus harder to devise a validation strategy

Management of Templates and Requirements Document

RDDV needs enhancements

Recognize entities and features

RDDV checks can invoke CheckMate Checkers

Enforcement of RDDV checks

CheckMate needs more sophisticated profile capabilities

Profiles execute different based on decisions and rules

Profiles and checkers “know” about RDDV checks

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Thank You!

Questions?