diseño para manufactura - upvpersonales.upv.es/~jugarcia/lionel/upv_2012_master_cad-cam... · post...

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Diseo para manufactura

: Ingeniera concurrente

Pr. Lionel ROUCOULES [email protected]

www.ensam.fr

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Who I am: brief curriculum

Professor at the Arts & Mtiers Paris Institute of Technology (France) Research at LSIS-IMS laboratory

Associate Professor at the University of Technology of Troyes (France) - Sept. 2000 Sept. 2008 Head of the ICD-LASMIS research team (jan. 2008 sept. 2008)

Head of Mechanical Systems Master course (jan. 2005 jan. 2008)

Teaching in the Department of Mechanical Systems Engineering

Research at LASMIS (Laboratory of Mechanical Systems and Concurrent Engineering)

Post Doc position at TU Twente (The Netherlands) - October 1999 August 2000

PhD thesis National Polytechnic Institute of Grenoble and Universidad Polytecnica de Valencia - 1999 Title: Methods and software for the contribution to the development of a computer-

supported integrated design environment.

MSc in mechanics - National Polytechnic Institute of Grenoble 1995

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What I am investigating for

Research topics:

Integrated design, Computer-Aided Design and collaborative software

environment. Model Driven Engineering.

DFX by least commitment approach (multi-physical modelling, DFM

modelling)

Industrialisation methods and tools

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ENSAM : Paris Institute of

Technology

An engineering school (Grande Ecole)

8 campus (BSc, MSc and Research) Paris

Chalon en Champagne

Metz

Bordeaux

Cluny

Lille

Aix en Provence (my campus)

Angers

3 Institutes (MSc course) Bastia

Chalon sur Sane

Chambery

Paris

Lille

Ch. en Ch. Metz

Angers

Bordeaux

Cluny

Aix en Pce

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Who are you ?

What are your expectations in attending this course ?

Who knows about ?

Concurrent and integrated engineering design

Design for X

Virtual prototyping

CAD, CAM, CAx and PLM

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Agenda : Diseo, manufactura y

innovacin

Los procesos de diseo como suporte a la razn de disear : quien,

que, cuando, porque pasamos de funciones hasta tecnologas,

geometra y manufactura.

Los modelos y sistemas de informaciones actuales para disear

(CAO, XAO, PLM..) y ensenar las limites des esas soluciones con

respecto al ideal de innovacin

El mtodo de DFX y entonces de DFM al justo necesario para

integrar manufactura y diseo

Los procesos de industrializacin para dominar los cambios con

respectos a nuevos productos, nuevo entorno industrial, nuevas

tecnologas de maquinas o herramientas

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Knowledge modeling of Design and manufacturing interface for DFM

approach during product development process. Application to foundry

process

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Introduction to current

practices in virtual

engineering

Issues of design and innovation

of complex system

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Preamble : design, CAD and PLM

in current industry?

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Product birth Which product (price, public,

date) ?

Design Which functions?

Which technologies ? Use (components, materials)

Manufacturing process and system

Usage phase Maintaining technology

Product dismantling Disassembly technologies

Recycling technologies

Industrial departments

Marketing

Design service

Manufacturing service

Purchase service

Maintenance Service

Design project and product

LifeCycle Marketing

Development

Sales

Maintenance

Recycling Industrialisation

Production

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Design project and milestones

Project driving

Task management (cf. product lifecycle)

Ressources management (Human, material, information)

Milestones for:

Decision making

Reduce feed-backs (Cf. integrated design)

Objectives driven project

Lancement dun

nouveau projet

ex-nihilo

J1 J2 J3 J4

Dveloppement

Conception dtaille

R&D Etude marketing Industrialisation

Dbut du

dveloppement

Industrialisation Prototypage Dbut avant

projet

Production

Vente

J5

Fin de projet

(Ou du produit)

J6 J0

Maintenance

Modification

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Examples

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Industrial development at Loral

Marketing International

Dveloppement Industriel

Formule & Timing

PVIS Cible

Quantits estimatives

Le brief marketing Maquettes/Dfinition de

la Gamme

Industrialisation 16

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IDEE AVANT-

PROJET PROJET

Dfinir le concept

et laborer le brief

Proposer et

prslec-tionner

des couples formule/

packaging

Affiner la dfinition

du produit

& Valider la faisabilit technique

du produit

Analy

ser le

s ris

ques

Fabrication et

conditionnement

Dveloppement formule

AC primaires et secondaires

Communication, mdia, hors mdia, RP, vnementiel

Merchandising et PLV / Echantillonage

Prparation des pays, prvisions et commandes

Slectionner les ides

Prparer le projet Dvelopper le produit

Prparer la commercialisation pays

Produire

Validation CDCE Validation CDCD Prsentation march

MAD Centrale

Development process: main

phases

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Development process: planing

Validation CDCD

MAD Centrale

Validation

conomique

Construction quation conomique

cible

Construction quation conomique

estimative

Construction quation

conomique de lct.

Validation CDCE

Prsentation march

Choix du nom Recherche de noms Nom

Cration PLV

Conception PLV

Appel d offre

Fabrication PLV PLV2

Concept

Formule

Publicit.&

Communi -

cation

Slection choix intentions publicitaires

Cration visuel

Phase ide

Phase avant projet

(cas dun dveloppement doutillage)

Phase projet

Fabrication AC conditionnement

Engagement march

Commercia-

lisation

Construction potentiel projet

Envoi book PV + PLV1

Envoi book PLV2

Engagement march

Dvelopt

Packaging

Slection packaging

Dfinition packaging

Conception technique AC

+Pr spcifications

Dveloppement Moule (essai + industriel) + Mise au point + homologations

ou Packaging

existant Dfinition Pack

Choix concept valuation

Formulation Approv. MP

Fabrication jus Tests marketing et tests labos

puis officialisation tudes march exploratoires

Mise au point + homologations

laboration des lments de communication

& publicit

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Ordre des tapes

du dveloppement

Dure et squence

relatives des tches PLANNING

Dcor

Flacon

Capot Jus

Industrial development actors

Production

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Marketing

Packaging

LAF

Usine :

Logistique

Packaging

Qualit

Achats

RAD

Labo

Compatibilit

Pilote

DGA

Fournisseurs

D.A.F DEVELOPPEMENT

TECHNIQUE

Direction Technique DPL

DGT

Industrial development actors

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Industrial development at

Bourjois

[Per 05]

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Development process: planing

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Plane development plan

Concept

Phase Definition

Phase

M14

M13

Ready for

Entry into

Service M1

Market

Opportunities

Identified M5

Instruction to

Proceed (ITP)

M3

A/C Concept

Selected

M9

Begin of

Final Assembly

M7

Go ahead

Product Idea

Established

M0 M4 A/C

Configuration

Baselined

M6 Authorization

to Offer (ATO)

M2 Standards and

Requirements

Available

M8 First

Metal Cut

M10 Power On

M12 Type

Validation

M11

First Flight

Analyze

Market Needs

Most

Promizing

A/C

Optimize Concept

On A/C Level

Consoli- date A/C Configu-

Finalize A/C Specifi-

Assure

Industrial

Launch Assemble

& Test

Sections

Conduct Final Assembly

Process Prepare

1st Flight

Achieve

Type Achieve

Operation

Complete

Basic

Identify Initiate

Manu-

Readi-

Observe Business

Concept ration Baseline

Cation &

Com-

mercial Proposals

Condition

facture of Parts

Manu-

facture of Parts,

Certifi- cation &

Analyze

Market Situation

ness

Develop-

ment

Development Phase Feasibility

Phase

Ground

Test &

Perform

Validate Standard Spec.

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Reactor development plan

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Reactor development plan and

vritual engineering

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Development plan at Johnson

Controls

Aronautique, automobile, tlphonie, multimdia, etc.

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Development plan at Johnson

Controls

PLUS

Reviews

1 Proposal 2 Product Feasibility 3 Design & Tooling 4 Production Validation 5 Launch

Product & ThemeDefinition Reviews(Internal/Customer)

11 22 33 44 55

CE&M Review

CE&M Review @ DVPlanned Completion

CE&MReview

@ PV Planned Completion

TargetedBusiness Plan

SOW (Quote) SOW (Revised)

ProgramBusiness Plan

CAR & TA Submission CAR & TA Approval

SOW (Revised)

SSOWs Written SSOWs Signed DV Tool Orders

Development eBOM

Parts Matrix

2D Theme Rendering Set 3D Theme Surface Models 3D Class A Surface

CAD Models / Layouts

Product Specifications FEA / Engineering Analysis

DFMEA (Actions & Dates Identified)

PFMEA (Actions & Dates Identified)

CAD Models (Class ASurface Incorporated)

EDP&R Build &Testing

DFMEA(Actions Implemented)

PFMEA(Actions Implemented)

CAD Detail Drawings

Tool, Gage & FixtureDesign

Plant Layout / Equipment Design

DV BuildInspection

Order DV Parts

Pull Ahead Production/PrototypeTooling, Gages & Fixtures

AssyCriticalDVP&R

CE&MReview

Production Control Plan

CustomerPart Approval

Complete DVP&RTesting

CompleteProduction Tooling

AssyPVP&RTesting

SupplierPart Approval

Complete Manufacturing Equipment

Order PV Parts

PV BuildInspection

DV CustomerShipments

Customer Shipments

Product Launch System Account FinancialManagement

Quality Objectives & Roadmap / Supplier AQP Report DV Control Plan / MSA

DV ManufacturingEquipment Construction

Key:Program

ManagementPurchasing Industrial

DesignEngineering Quality Manufacturing Suppliers

Revision: October 2005

PhaseExit

PhaseExit

PhaseExit

Program Award

Program Award

ProductionRepresentative

Product


Product

PhaseExit

PhaseExit

Start ofProduction

Start ofProduction



PV Tool Orders

CE&M& PSDR

Product Feasibility

Product FeasibilityProgram

Milestones

Program

Milestones

CustomerShipments

Product &Theme Definition


Pull Ahead Production Tool Release


Process Flow Diagram / DFM&A

Plant Launch Glide Path

Sourcing Requirements

Review

Tooling Requirements

Review

Award Letter

QBOM

Final ProductionRelease


PLUS

Reviews

1 Proposal 2 Product Feasibility 3 Design & Tooling 4 Production Validation 5 Launch

Product & ThemeDefinition Reviews(Internal/Customer)

11 22 33 44 55

CE&M Review

CE&M Review @ DVPlanned Completion

CE&MReview

@ PV Planned Completion

TargetedBusiness Plan

SOW (Quote) SOW (Revised)

ProgramBusiness Plan

CAR & TA Submission CAR & TA Approval

SOW (Revised)

SSOWs Written SSOWs Signed DV Tool Orders

Development eBOM

Parts Matrix

2D Theme Rendering Set 3D Theme Surface Models 3D Class A Surface

CAD Models / Layouts

Product Specifications FEA / Engineering Analysis

DFMEA (Actions & Dates Identified)

PFMEA (Actions & Dates Identified)

CAD Models (Class ASurface Incorporated)

EDP&R Build &Testing

DFMEA(Actions Implemented)

PFMEA(Actions Implemented)

CAD Detail Drawings

Tool, Gage & FixtureDesign

Plant Layout / Equipment Design

DV BuildInspection

Order DV Parts

Pull Ahead Production/PrototypeTooling, Gages & Fixtures

AssyCriticalDVP&R

CE&MReview

Production Control Plan


Complete DVP&RTesting

CompleteProduction Tooling

AssyPVP&RTesting

SupplierPart Approval

Complete Manufacturing Equipment

Order PV Parts

PV BuildInspection

DV CustomerShipments

Customer Shipments

Product Launch System Account FinancialManagement

Quality Objectives & Roadmap / Supplier AQP Report DV Control Plan / MSA

DV ManufacturingEquipment Construction

Key:Program

ManagementPurchasing Industrial

DesignEngineering Quality Manufacturing Suppliers

Revision: October 2005

PhaseExit

PhaseExit

PhaseExit

Program Award

Program Award


Product


Product

PhaseExit

PhaseExit

Start ofProduction

Start ofProduction



PV Tool Orders

CE&M& PSDR

Product Feasibility

Product FeasibilityProgram

Milestones

Program

Milestones

CustomerShipments





Process Flow Diagram / DFM&A

Plant Launch Glide Path

Sourcing Requirements

Review

Tooling Requirements

Review

Award Letter

QBOM



ELABORATION

Refine the definition of

the product,

Define and baseline an

ARCHITECTURE,

and

Develop a more precise

plan for its development

and deployment.

Design Review

SRS

SAD

SIP

SVP

REALIZATION

Product is built,

up to the point where it can be

put in the hands of its end-

users

Qualification

Review

SIR

SVR

MRS

SEM

MANUFACTURING

Product is transitioned to manufacturing,

and delivering,

Manufacturing

Review

SVS

PMA

SW Development Plan

SW Quality Assurance Plan

SW Requirements Specification

SW Architecture Design

SW Integration Plan

SW Validation Plan

SW Integration Report

SW Validation Report

Manufacturing Requirements Specification

SW Eeprom Mapping

MAINT-

ENANCE

Product

is

modified

on

customer

requests

SVS SW Version Sheet

Post Mortem Analysis

PREPARATION

Define the

Overall

scope of the

Project

Define

preliminary

Architecture

Plan Next

Phases

SDP

SQAP

Plan

Review

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System engineeringexamples

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AFIS : System engineering concerns a se of acitivities and

actors that are processed for product or system development.

V development cycle and system

engineering

Besoins

Clients

Rponses

solutions

physiques

Dfinition

Organes

Dfinition

composants

organes

Concrtisation

des

organes

Test

validation

composants

Test

dfinition

organes

Validation

physique

Validation

besoins

Plan de tests

Plan de tests

Plan de tests

Spcifications

Techniques de

besoin

Spcifications

Techniques de

Gnrales

Spcifications

Techniques de

Dtailles

Spcifications

Techniques de

ralisation

Dossiers de

validation

Dossiers de

validation

Dossiers de

validation

Dossiers de

validation

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Besoins

Clients

Rponses

solutions

physiques

Dfinition

Organes

Dfinition

composants

organes

Concrtisation

des

organes

Test

validation

composants

Test

dfinition

organes

Validation

physique

Validation

besoins

Plan de tests

Plan de tests

Plan de tests

Spcifications

Techniques de

besoin

Spcifications

Techniques de

Gnrales

Spcifications

Techniques de

Dtailles

Spcifications

Techniques de

ralisation

Dossiers de

validation

Dossiers de

validation

Dossiers de

validation

Dossiers de

validation

LAnalyse

Fonctionnelle

Quality

Functional

Deployment

Simulations de

comportements

Calcul

Cotation

Fonctionnelle

Simulation de

Procds

LAnalyse Modes de

Dfaillances de

leurs Effets et leur

Criticit

Essais Physiques

Plans

dExpriences

Taguchi

Six Sigma

Simulation des

contrles

commandes

machines Simulation des

flux et stocks

Gammes de

Fabrication dAssemblage Simulation de

production

Analysis models and V

development cycle

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V development cycle and plane

breakdown (3 levels)

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V development cycle and virtual

engineering software

Feasibility Concept Definition Development Series

M3 M5 M7 M13

Numerical Command

Tooling Master Geometry

Assembly

Instructions

Tooling Principles

Tooling Space Allocation

Tooling Frontier Models

Manufacturing Plan

Ind

ustr

iali

zati

on

Supportability Analysis

Supportability Discrepancies

Support Specification

Support Objectives

Su

pp

ort

Master Geometry

Frontier Models

Definition Model

Space Allocation

Stress Design Reference Base

Design Principles

Definition Dossier

Air

cra

ft

Systems Architecture

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V development cycle for reactors Expression du

besoin

Nouveau projet

avionneur

Spcification du

propulseur

Conception gnrale

(Autonomie, Consommation,

Intgration lavion)

(Positionnement des modules, Concepts

de montage/configurations, Allocations

despace de conception 3D)

Conception dtaille

Intgration des modules

Design Simulations

mcaniques,

maintenance

Industrialisation

Machines

dessais,

srie

Intgration des

lments

Test au sol

Bancs dessais

Test en vol

Maintenance

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CAD-FEA simulation feedbacks

Conception

dtaille

Validation du

modle/simulation

Dfinition

gnrale du

produit

Objet Virtuel

Analyse

contextuelle

Validation gnrale de la

conception/ Contexte

maquette numrique

Rfrentiel/Spcificati

on de simulation

Maillage des lments

Conception pour la

simulation

Modle lment finis

intgr

Analyse/Validation

des rsultats

Boucle simulation Design

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Travail en itration (dans chaque phase)

et incrmentation (dune phase lautre)

1 ou plusieurs cycles en V sont

appliqus dans chaque phase

Chaque phase/cycle gnre un

prototype Validation

Integration

Unit. Tests

Code

Specification

Pre. Design

Det. Design PREPARATION MANUFACTURING REALIZATION ELABORATION

Phase Exit: Assess if Defined Objectives have been met, Deliverables completed, Models updated.

Define the

Overall scope

of the Project

Define

preliminary

Architecture

Plan Next

Phases

Refine the

definition of the

product,

Define and

baseline an

ARCHITECTURE

,

and

Develop a more

precise plan for

its development

and deployment.

Product is built,

up to the point

where it can be

put in the hands

of its end-users

Product is

transitioned to

manufacturing,

and delivering,

MILESTONE

DR M

R

SR PR

ITERATION

+ Maintenance Phase

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Cycle en V dun logiciel

embarqu phase ralisation et outils/acteurs

Une quipe

ddie un seul

projet

CodingCodingCoding

RequirementsSpecificationRequirements

RequirementsSpecificationSpecification

ArchitectureDesignArchitecture

ArchitectureDesignDesign

DetailedDesignDetailed

DetailedDesignDesign

ValidationTestValidation

ValidationTestTest

IntegrationTestIntegration

IntegrationTestTest

UnitaryTestUnitary

UnitaryTestTest

EE--CARCARGraph CoverageGraph CoverageGraph DebugGraph Debug

StateMateStateMateRapid / VAPSRapid / VAPSSA/RT Select YourdonSA/RT Select YourdonCustomer Interactive Q/ACustomer Interactive Q/A

Standard 3 LayersStandard 3 LayersSoftware ArchitectureSoftware ArchitectureVisioVisioUML Artisan / RoseUML Artisan / Rose

GraphDesignerGraphDesignerJ.I.L.J.I.L.

Visual C++ 6.0 & Cross compilerVisual C++ 6.0 & Cross compilerQAC Misra Compliance ModuleQAC Misra Compliance Module

Programming RulesProgramming Rules

TestU EnvironmentTestU EnvironmentCC--Cover CoverageCover CoverageComponent CheckListComponent CheckList

EE--CARCARRR--CARCARSVLSVL

SCEPTRESCEPTRE

Delivery FormDelivery Form

PV

CS

P

rom

otio

n

PV

CS

P

rom

otio

n

MSMS--ProjectProjectProject FolderProject Folder

Project

Leader

Software

Coordinator

Sw Validation

Team Leader

Software

Lead

Engineer

Software

Auditor

Validators Software

Implementers

Validation

Expert

Software

Team Leader

Sw

Requirements

Engineer

Software

Product

Integrator

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Key issue: design process

modelling and rationale

Design process Customer requirements

Product models for VP development

Costs

Ress. Software

Human Ressources

Material ressources

Quality, norm

Industrial

context

Physical and digital mock-up

What have been the main design methods ?

Which product models ?

How to improve software ?

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Concepts, ideas, philosophies to change design reasoning

and organisation toward product innovation

Design methods

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Industrial organisation evolution

for design process

Information transfer and prescription

Over the wall approach

Information exchange and collaboration (1990th)

Concurrent engineering

Integrated design




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Clarifying requirements

Reference : Pahl & Beitz

(D), Wallace et al. (GB),

Ullman (USA),

Roozenburg (NL)

Method

Systematic design

process

Objectives:

To go to industrial

approach of the design

Design method Systematic

design

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Solutions

applicables

Problme

dfini Barrires

Modle 1

Modle 4

Modle 3

Modle 2

Concepts

gnraux

Ou

tils

TR

IZ

1-Documenter, rassembler les lments,

2-Modliser le problme sous une forme de la mthode

3-Utiliser les outils TRIZ ==> solutions gnriques

4-Interprter les solutions gnriques

5-Evaluer, dcider

Reference : Altshuler (Russia)

Method

Patent analysis

Creative theory proposal

Objective:

Find innovative solution

Design method TRIZ

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Reference: Hatchuel (F)

Method

Creative theory based on

Concept and Knowledge

analysis

Objective:

Find innovative theory based

on product line improvement

Design method C-K theory

Concept space Knowledge space

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Funcitonal space Solution space

Comparison

Reference : Suh (Corea),Yoshikawa & Tomiyama (Japan)

Method Domain space modelling

Matrix-based relationship

Objective Axiomatic approach of the design to

tackle complexity

Design method Axiomatic

Independency axiom

DP &FR must be independant.

Information axiom

Less parameters for less

complexity.

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Dterminer

les besoins

commerciaux

BESOINS Caractriser

le type de

produit

Considrer

les types

de fabrication

Dterminer

les modes de

production

Dfinir

les principes

de solutions

Enquter

auprs des

utilisateurs

Etudier

le march

Dfinir

le produit

Dterminer

les principes

de production

Prparer

la vente

Modifier

pour la

fabrication

Prparer

la

production

Produire

Adapter

le produit

Vendre

Reference : Andreasen (Danemark)

Method Design expert collaborative requirements based

Objective To take into account multiple-points of view during the design

process

Design method Concurrent and

integrated design

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Design concept

Design for assembly

Best design concept

Design for manufacture

Prototype

Detail design for minimum

manufacturing cost

Suggestion for simplication

of product structure

Reference : Boothroyd (USA), O'Grady, Ashby (GB)

Method

Design for X based on product assesment and guidelines

Objective To take into account multiple-points of view during the design

process


integrated design

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Reference : Tichkiewitch (France)

Method

Design expert collaborative requirements based

Objective

To take into account multiple-points of view during the design process

To add rationale in the design chain


integrated design

B A

Structure complte

Detailed design

assemblage

calcul

de structure

.......

Transmettre

un couple

A B

A

B Contact

solide / solide

Fonction Principe

physique

Technologie

aju

ste

ment

serr

A

B Ra

Ra

: surfaces non dfinies

surfaces fonctionnelles

dusage

technologue

mcanicien ........ Conceptual design Embodiment design

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To set formal data structure and relationships that

trace and model specific phenomenon

Information modelling

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Product modelling (what ?)

Functional representation

Product breakdown

Design process modelling (Who, When, how ?)

Tasks representation

Industrial organisation modelling

Performances driving.

3 levels of information modelling

for design rationale

Design process Customer

requirements

Product models

Cost

Software

Human resources

Material

resources

Norm

Industrial

context

Product assesments




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Computer support for information modelling and

behaviours simulations

and software for digital design

chain




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Expertise GRAI-R&D

GRAI-R&D Liaison IPPOP

Crer Fonction Dtruire FonctionCrer Niveau Dtruire Niveau

Plan Action

Crer Lien

Informationnel

Dtruire Lien

Informationnel

Crer Cadre de

Dcision

Dtruire Cadre de

Dcision

Crer Centre de

Dcision

Dtruire Centre de

Dcision

Plan Objet

Grer les Infos

ProjetsPlanifier

Grer les

RessourcesGrer les Besoins

Grer la Connais.

Produit ProcessusConcevoir

Infos

Externes

Infos

Externes

Infos

Internes

Infos

Internes

Niveau

Stratgique

Niveau

Oprationnel

Niveau

Tactique

H : x ans

P : y mois

H : x mois

P : y semaines

H : x semaines

P : y jours

Sauver Structure

GRAI R&D

Nouvelle Structure

GRAI R&D

Organiser la

capitalisation

Dfinir les

activits de

conception

Dfinir les

besoins des

utilisateurs

Superviser

les activits

de

capitalisation

Dfinir les

activits

lmentaires

Vrifier

ladquation

spcifications

-solutions

Suivre

lexcution

des activits

individuelles

Planifier les

relations avec

le client

Capitaliser

linformation

technique

Grer les flux

dinformation

et dployer

les

procdures

Planifier les

projets

Dfinir les

RH et la

stratgie /

technologies

Synthtiser

lavancement

des projets

Planifier les

activits et

organiser

les projets

Affecter les RH

et ajuster les

investissements

Planifier les

activits

individuelles

Enterprise modelling for

performances driving

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Input Output

Control

Mechanisms

Manufacture

Milling Assembly

2

A0

1 3

Part clamping

22

Milling

A-0

4

21

23

Supply stocks

A2 Operation 1

Operation 2

Design process modelling: IDEF or SADT actigram

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Systme

multibroch

es

Milieu

extrieur

Fp2

C3

C4

Perceuse Forets

Fp1

C5

Oprateur Pice

15 1 Palier avant PA 11

14 1 Chambre tournante X 2 CrNi 18-10 (Z 2 CN 18-10)

13 2 Rondelle de rglage

12 1 Chapeau X 2 CrNi 18-10 (Z 2 CN 18-10)

11 2 Bute billes

10 1 Bec de dosage X 2 CrNi 18-10 (Z 2 CN 18-10)

9 3 Joint torique 91,4 x 5,3 Silicone


7 1 Piston Tflon

6 1 Bride Ertalon

5 7 Ecrou molet M10 Norelem

4 1 Pignon rcepteur ( Z=35 , m=6 ) Ertalon

3 1 Manivelle X 8 Cr 17 (Z 8 C 17)

2 1 Pignon moteur ( Z=35 , m=6 ) C 35 (XC 35) Nickel

1 1 Bti

Rep. Nbre Dsignation Matire Obs.

POMPE DOSEUSENomenclature

partielle

Requirements specification

Conceptual design

Embodiment design

Detail design

Function

Technology

Form features

Behaviours

Product modelling

62

Cours_Benoit/NF15_Fonct_struct_A05.pptCours_Benoit/NF15_Fonct_struct_A05.pptCours_Benoit/NF15_Fonct_struct_A05.ppt

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Who will use the product ? On what the product is actuating?

What is the customer need ?

Manufacturers Parts

To increase the

production rate

System

Product modelling functions : La bte a corne

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Configuration : drilling

Fp1 : To drill 3 holes in a raw

Fp2 : To transmit the power

C3 : To resist to environment

C4 : To protect the operator

C5 : To clamp the cutting tools

C6 : To clamp the driller

System

environment

Fp2

C3

C4

Driller Drill Tools

Fp1

C5

Operator Part

* APTE (APplication aux Techniques d' Entreprise) or Pieuvre

Product modelling functions : Interactions Graph*

C6

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* Functional Analysis System Technique

BRAS

UTILISATEUR

F1 TRANSMETTRE

MVT DE ROTATION

BRAS/BATI

ASSURER LA

LIAISON COMPLETE

AVEC LE BRAS

ASSURER LA

LIAISON COMPLETE

AVEC LE BATI

GUIDER EN

ROTATION

LE BRAS/BATI

PERMETTRE

UTIL. DEXTRAIRE

SYSTEME/MILIEU

F2

UTILISER

ENERGIE

HYDRAULIQUE ASSURER

LIAISONS

DEMONTABLES

RESPECTER

LENVIRONMENT

EVACUER

HUILE

ISOLER

ALIMENTATION

HYDRAULIQUE

BRAS

BATI

ALIMENTATION

HYDRAULIQUE

BRAS

BATI

BRAS

BATI

HUILE

HUILE

F11

F12

F13

F14

F221

F222

F21

F22

ALIMENTATION

HYDRAULIQUE

Function Which

objective ? How ?

When ?

When ?

Product modelling functions : FAST*

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Function 1

Function 11 Function 12 Function 13

Function 111 Function 112 Function 121

Function 1111

Product modelling functions : functionnal breakdown

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Functional modelling

Innovation and technology selection

APTE Avt et APTE Fonc

BDF

CdCF et CdCF 2

TAF

http://www.tdc.fr

Invention WorkBench (http://www.ideationtriz.com)

QFD Capture

QFD Designer

TechOptimizer (http://www.invention-machine.com)

TRIZZ Explorer (http://www.insytec.com)

Software for functional modelling

and technology selection

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Product

S/s-ens. A S/s-ens. B S/s-ens. C

Module A2 Module A1

Part

A1B Part A1A

Product modelling

breakdown : Structural tree

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15 1 Palier avant PA 11

14 1 Chambre tournante X 2 CrNi 18-10 (Z 2 CN 18-10)

13 2 Rondelle de rglage

12 1 Chapeau X 2 CrNi 18-10 (Z 2 CN 18-10)

11 2 Bute billes

10 1 Bec de dosage X 2 CrNi 18-10 (Z 2 CN 18-10)



7 1 Piston Tflon

6 1 Bride Ertalon

5 7 Ecrou molet M10 Norelem

4 1 Pignon rcepteur ( Z=35 , m=6 ) Ertalon

3 1 Manivelle X 8 Cr 17 (Z 8 C 17)

2 1 Pignon moteur ( Z=35 , m=6 ) C 35 (XC 35) Nickel

1 1 Bti

Rep. Nbre Dsignation Matire Obs.

POMPE DOSEUSENomenclature

partielle

Product modelling

breakdown : BOM (Bill Of Material)

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Product modelling : functional Bloc-diagramme

E2

E3

Componant 1 Componant 2

Componant 2 FP1

E1

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Product modelling : function-structure Matrix

F 1

F 1

1

F 1

2

F 1

3

F 1

11

F

121

System

S/s-ens. A

M B2 M B1

P B1A

S/s-ens. B

P B1B

Surface 1 Surface 2

Surface 3

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B-Rep Modelling (Boundary Representation)

Point/Ligne/Surface/Volume

CSG Modelling (Constructive Solide Geometry)

Boolean operations based on primitives

Reprsentation B-Rep de la gomtrie

Cylindre 1 Cylindre 2

Fusion

CSG tree of a part

Remark: Usually, both models

are coupled (cf. OCC).

Product modelling : Form

modelling : CAD

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Product modelling: Behaviours

assesment

(processes

simulation)

FEA analysis model Limit conditions.

Loading.

Material behaviour.

Kinematics model Kinematic data.

Dynamic data (masse).

Motion laws (input).

Manufacturing model Manufacturing plan

Cutting tool and trajectory.

Material and cutting parameters

NC machine and post-processor

X models

73

../../../../Donnees/Lionel/enseignement/cs05/POT_NNOR.gif../../../../Donnees/Lionel/enseignement/cs05/simulation_usinage.AVIC:/Donnees/Lionel/enseignement/ENSAM_CER_Aix/FITE_IND_Lionel_Roucoules/IND_CM_Fichiers/IND_CM_Intro_Chaine_Numerique.ppt

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Limits of the digital design chain

Overview of virtual

engineering comercial software

and main functionalities

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Overview of commercial software

and main functions: product information

CAD-CAM: product

breakdown (part or

assembly) and

construction history

management

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CAD-CAM :

relations and

expert rules

integration

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CAD-CAM : management

of large assemblies with

huge part diversity

(heterogeneous software)

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CAD-CAM : integration of expert

modules

FEA,

CAM,

Ergonomic senses, etc.

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CAD-CAM : digital mockup, augmented reality, animation

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Independant expert software: FEA, kinematics and dynamic

analysis, tolerancing, CAM, etc.

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Overview of commercial software and

main functions: design process information

Project planning management: Ms/Project, PSN, Planner

Tasks planning

Milestones definition

Ressources management

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main functions: product and design process information

PLM system: product

breakdown and list of

articles (objects)

Management of objects

related documents

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PLM Systems: documents management CAD, MS Office

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PLM Systems:

management of product

configurations

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PLM Systems: workflow for

documents lifecycle management

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PLM system: digital mock-up light visualisation

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main functions: organisation and design process information

PLM System: task notfication with related documents via e-mail

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main functions: organisation and design process information

PLM System: team resources

management (access rights,

roles)

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main functions: collaboration

CSCW software : Lotusnotes, Sametime, Exchange, Quickplace,

Mayeticvillage

Email, video-conferencing

Document sharing

Workflow

Application sharing

Collaborative portals

Communication

Coordination Collaboration

Vido

Conferencing

E-mail

BD

spciale

Workflow

Bulletins

Web

Editeurs

coopratifs

Gestion

de runions Aide la

dcision

[Godart, 2000]

Workflows

management

Communication

tools

Collaborative

spaces

CSCW

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Synthesis current limits

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Synthesis: (models software)

vs. methodological concepts

Function modelling are not so far linked to structural parameters

How to drive performance and re-design

Structural breakdown gives the final state of the product

What about who and when ?

CAD (i.e. form) modelling only treats nominal topology information and is used as the starting point of product assessment

What about design rationale and product lifecycle?

Behaviours assessments are not linked among each others and not always linked to the geometry

What about integrated design (rationale) and innovation (least commitments)?

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Design is a multi-actors activities

centred on:

CAD modelling

PLM systems

There is a huge lack of experts

(actors) information synthesis:

This information are mainly used

in a reactive and analysis way

CAD model is not representative

of experts' design intents

Every product analysis are not

linked (model and software

interoperability)

Synthesis: models vs.

methodological concepts

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To propose method and model to support an expert centric design process To set a proactive position of

experts to generate alternatives and select solutions

To manage information of the whole product lifecycle (what, who, when, why)

To develop software demonstrators to valid the concepts Expert analysis software

Specific use of CAD and PLM solutions

To develop scenario and examples

What is the target complex

system engineering

Product creation based on

expert information synthesis

Solution du produit

(choix final)

Donnes

mtier +

? ?

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Introduction to

integration concepts (some solutions)

- Information related to product development (PPO and PPR)

- Different experts: concepts of Design For and Design to : DFM, DFA, DFR, LCA

- Different disciplines involved in multi-physical product development (mechatronic systems)

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DFM, DFA, DFR, LCA

Expert integration: Design

For and Design to

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To propose method and model to support an expert centric design process To set a proactive position of

experts to generate alternatives and select solutions

To manage information of the whole product lifecycle (what, who, when, why)

To develop software demonstrators to valid the concepts Expert analysis software

Specific use of CAD and PLM solutions


What is the target complex

system engineering



Design final solution

LC information +

? ?

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Product birth Which product (price, public,

date) ?

Design Which functions?

Which technologies ? Use (components, materials)

Manufacturing process and system

Usage phase Maintaining technology

Product dismantling Disassembly technologies

Recycling technologies

Industrial departments

Marketing

Design service

Manufacturing service

Purchase service

Maintenance Service

Design project and product

LifeCycle Marketing

Development

Sales

Maintenance

Recycling Industrialisation

Production

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V development cycle for reactors Expression du

besoin

Nouveau projet

avionneur

Spcification du

propulseur

Conception gnrale

(Autonomie, Consommation,

Intgration lavion)

(Positionnement des modules, Concepts

de montage/configurations, Allocations

despace de conception 3D)

Conception dtaille

Intgration des modules

Design Simulations

mcaniques,

maintenance

Industrialisation

Machines

dessais,

srie

Intgration des

lments

Test au sol

Bancs dessais

Test en vol

Maintenance

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Design For Manufacture (DfM)

Product-Process Identification

Analytic, Numeric,

Experimental

Product-Process Integration

To select manufacturing

processes as soon as possible:

manufacturability assesment.

Definition of product

parameters

Design For Assembly (DfA)

Design For Recycling (DfR)

Design For Maintainability

(DfMa)

DFX concepts: Design for

ease one other activity

Processes

Processes list

Parameters list

Parameters range of

values

Product

Topology (form, dim)

Tolerancing (dim, form,

Ra)

Gradients

Database (P-P et

hypothesis)

Analytic

Experimental

Numric

PPd (i) = ID(ij)*PPf (j)

(overview

research)

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Objectives

Asses the impact of every

phase of the product lifecycle

on the objective

Development

Industrialisation

Assess the global objective on

the whole LC

Identify relations for impacting

the technologies selection

Examples

Design To Cost

Green Design

DTX concepts: design to

reach one objective

March

Marketing

Faisabilit

Dveloppement

Commercialisation

SAV

Recyclage

industrialisation

Production

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LC information integration

Some examples

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Process selection and

integration in product design

Process planning modelling

Rational CAD modelling issued

from process planning

Manufacturability analysis

during product design

Product-Process identification

DFM: Product-Process

integration

-0,10

-0,08

-0,06

-0,04

-0,02

0,00

0,02

0,0 1,0 2,0 3,0 4,0 5,0 6,0 7,0 8,0 9,0 10,0

Abscisse (mm)

Flche (mm)

Simulation - Longitudinal

Simulation - Transversal

Exprimentation - Extrapol du rayon Longitudinal

Exprimentation - Extrapol du rayon Transversal

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Product Life Cycle Analysis

Modelling and impact

assessment

Analysis of technological

changes

Function

Manufacturing

Materials

Alternatives comparison and

decision making process

LCA: Life Cycle Analysis and

integration in product design

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Safety analysis

Maintainability planing and

optimisation for reducing cost

(DTC) and impacting product

design (DFMa)

Disponibility with respect to

maintainability

Joint modelling of

maintainabiliy and disponibility

plans (with respect to product

missions)

DFMa: safety, maintaining plan

and product design

Intrinsi

c

Qualit

y

Robustnes

s to the

stress

Reduction

of the

stress

Certification

Tests

Protection

from the

overloads

Design,

Production,

Integration

Specification,

Integratioin

Means to

reduce the

overloads

Operating

conditions

Reliability

control on

life cycle

Component

quality

Overloads

External

stresses

Life

profile

Integrator

field of

actions

System

design

Integrator

process

Customer

Utilizatio

n Manual

Syste

m

Customer Integrator

Design Process

Equip-

ment

Compo-

nant Supplier

Specification to the supplier

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Advances for information

modelling multi-expert and multidisciplinar of the entire product life

cycle

- Multi-level modelling of product information: a by least commitments approach

- Design and manufacturing process modelling (Product-process integration)

- Resources modelling and integration PPRO

Remark : overview of the approaches (references can be read for

further details)

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Function modelling are not so far linked to structural parameters

How to drive performance and re-design

Structural breakdown gives the final state of the product

What about who and when ?

CAD (i.e. form) modelling only treats nominal topology information and is used as the starting point of product assessment

What about design rationale and product lifecycle?

Behaviours assessments are not linked among each others and not always linked to the geometry

What about integrated design (rationale) and innovation (least commitments)?

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Multi-level modelling of product

information: by least

commitments approach

Joint modelling of design

process and manufacturing

plan (product-process

integration)

Resources and design process

integrated modelling PPRO






LC information +

? ?

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cycle

- Multi-level modelling of product information: a by least commitments approach

- Design and manufacturing process modelling (Product-process integration)

- Resources modelling and integration PPRO

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Product modelling (what ?)

Functional representation

Product breakdown

Design process modelling

(Who, When, how ?)

Tasks representation

Industrial organisation

modelling

Performances driving.

Remind: 3 levels of information

modelling

Design process Customer

requirements

Product models

Cost

Software

Human ressources

Material ressources

Norm

Industrial

context

Product assesments

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Expert integration and solution convergence

A by least comitments

approach

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Individual and asynchronous

activities

Each one generates and assess

alternatives related to his

specifications

Collaborative synchronous or

asynchronous activities

Non planned activities detected

in case of conflicts

Planned activities (i.e.

milestones) for decision making

Remark: who starts?

Data pushed activities

Engineering: expertises and

collaborations toward the design solution

Expertise 1 A11

Expertise 2 A12

Collaboration A13

Product

data

Product

data

Product

data

Product

data

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What is the initial product state

(CAD vs. specifications)

Analysis (i.e. Reactive) approach

CAD model is taken as an input of the analysis

Manufacturability is assessed

Feed backs are given to the design

What if approach (i.e. Redo until right approach)

CAD model and current manufacturing process is given

Processes alternatives are studied with respect to product

specifications

Synthesis (i.e. Proactive Right the first time)

approach

Product specifications are given (i.e. functional surfaces)

Process alternatives selection is done

Product alternatives are then defined with respect to

process alternatives

Milling

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specifications


approach





Milling What if

casting?

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specifications


approach





Milling

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(CAD vs. specifications): example

Alternative n1

Extrusion (stock creation)

Contouring

Pocketing

Pocketing

Drilling

Alternative n2

Casting

Contouring

Extrusion

dies

radius End mill

radius

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Do not over-constrain the

design solution

Foster proactivity than

reactivity

To take profit of product data

range of values to go toward

innovative solutions

Let the design solution emerge

from information synthesis

Knowledge synthesis for

design rationale

Engineering: expertises and

collaborations by least comitments

Time

Q : Information

V : range of

values

Collaborative

decision

making

Information

synthesis

Expertise 1 A11

Expertise 2 A12

Collaboration A13

Product

Data

Product

Data

Product

Data

Product

Data

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LC information +

? ?

Usage concept: conceptual

and embodiment design

State of the arts (Bloc-diagram,

Bond-graph, FBS, Malin)

Energetic flows modelling

Expert integration and

multiple-view breakdown

Multi-details

Multi-concepts (CIFB)

Mutli-representations

(software)

Multi-level modelling (and

simulation ) of product information

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Example : solution concepts selection and form

features creation

Usage concept: function-

structure and energetic flows

modelling

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Moteur (Wm, Cm)

Hlice (Wh, Ch)

Accouplement

?

Transmettre un couple

entre larbre et lhlice

Couple C (N.m)

Principe de laction-

raction (contacts

mcaniques)

(Cm/h=Ch/m)

Ch Moteur

Wm

Cm Hlice Wh

Wm

Wh

pertes

Cm

Ch

Moteur Hlice

Wm Wh

Encastrement

Cm

Ch

Poulie-Courroie

Contact

Clavette

Cannelure

Poulie-courroie

Engrenage

Joint de cardan

Joint lastique

Delvion example

Accouplement poulie-courroie

Rendement

Rapport de rduction

Frottement

Entraxe

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Delvion example


entre larbre et lhlice

Couple C (N.m)

Accouplement poulie-

courroie

Rendement

Rapport de rduction

Frottement

Entraxe


raction

(Cm/h=Ch/m)


entre larbre et la poulie

dentre

Couple C (N.m)


raction (contacts

mcaniques)

(Cm/pe=Cpe/m)

(C=Pmc*Scontact)


entre la poulie dentre

et la poulie de sortie

Couple C (N.m)


entre la poulie de sortie

et lhlice

Couple C (N.m)


raction (contacts

mcaniques)

(Cm/pe=Cpe/m)


raction (contacts

mcaniques)

(Cm/pe=Cpe/m)

Contact Solide-Solide

Surface de contact

Matriaux

Contact Solide-Solide

Surface de contact

Matriaux

Courroie

Frottement

Surface de contact

Matriaux

Entraxe

Rapport de rduction

Wm Wpe

Cm Cpe

Poulie entre Wps

Wh

Ch

Poulie sortie

Hlice

Wh

Ch

Cps

Wce Wcs

Courroie

pertes

Cce Ccs

Pertes :

Glissement

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Wm Wpe

Cm Cpe

Poulie entre

Poids Vx

0 0

Bti

Liaison Pivot

Wps Wh

Ch

Poulie sortie

Hlice

Wh

Ch

Cps

Wce Wcs

Courroie

pertes

Cce Ccs

Pertes :

Glissement

Liaison Pivot

Vx

0

Liaison enc. Avec avion

Delvion example Assurer la liaison linaire

annulaire entre la poulie

dentre et le bti

{CA}p/b

Assurer la liaison rotule

entre la poulie dentre

et le bti

{CB}p/b


raction (contacts

mcaniques)

(Cm/pe=Cpe/m)

(C=Pmc*Scontact)

Pallier mcanique

Pallier lisse

Roulement billes CR

Pallier hydrodynamique

Pallier magntique

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Wm Wpe

Cm Cpe

Poulie entre

Poids Vx

0 0

Bti

Liaison Pivot

Wps Wh

Ch

Poulie sortie

Hlice

Wh

Ch

Cps

Wce Wcs

Courroie

pertes

Cce Ccs

Pertes :

Glissement

Liaison Rotule

Vx

0


Delvion example

Liaison LA

0

Vx

Roulement 1

Vx

Vx

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Wm Wpe

Cm Cpe

Poulie entre

Poids Vx

0 0

Bti

Liaison Pivot

Wps Wh

Ch

Poulie sortie

Hlice

Wh

Ch

Cps

Wce Wcs

Courroie

pertes

Cce Ccs

Pertes :

Glissement

Liaison Rotule

Vx

0


Delvion example

Liaison LA

0

Vx

Roulement 1

Vx

Vx

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From usage to experts

integration

Every surfaces of the system do not

have their rationale and are not

therefore created !

Those form features have then to be

created in another way (experts

information synthesis).

Proactive approach of DFX methods.

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Multi-details

Multi-concepts (FBS, CIFB)

Multi-representations (logiciel)

Experts information (i.e.

Knowledge) synthesis and

multiple-view modelling

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LC information +

? ?

Usage concept: conceptual

and embodiment design

State of the arts (Bloc-diagram,

Bond-graph, FBS, Malin)

Energetic flows modelling

Expert integration and

multiple-view breakdown

Multi-details

Multi-concepts (CIFB)

Multi-representations

(software)

Multi-level modelling (and

simulation ) of product information

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Mechanical analysis

Inertia

loading

Material

E

Manufacturing

Process plan

Phase Form feature

(CAD)

Multiple-views concept

In a design process, the product is obviously seen differently by

every participant (i.e. design intents). This depends on the task of

each one that has to be executed.

Several informations have then to be taken into account (=

information chain on the entire LC).

Introduction : why do we need

multiple-views modelling

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Name: vocabulary used for somebody to describe his

activity and the product

Characteristics: Data that decribe a feature

Rules: Intern behaviour of the feature (relations among

characteristics)

A generic model for information modelling (ontology)

Beam

Diameter

Length

Inertia

Inertia =

Drilling

Diameter

Cutting speed (Vc)

Spindle Speed

Spindle speed = 32

. 4D

D

Vc

.

.1000

Experts features concept

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Beam: Poutre1_arbre

Diameter: 20mm

Length: 70mm

Inertia: 15700mm4

Inertia = 32

4D

70

20

Features and product modelling

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cycle

- Multi-level modelling of product information: a by least co

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