CE10 - Usine du futur : Homme, organisation, technologies

Adaptive Quality Control in Tolerancing and Production Strategies for the Economic Production of High Precision Products – AdeQuaT

AdeQuaT

Adaptive Quality Control in Tolerancing and Production Strategies for the Economic Production of High Precision Products

Motivation

Motivation: Key functions of complex products often can only be realized by precision component use. Thus, producers are confronted with high quality requirements, cost pressure and a rising number of product variants. Especially, micro components, which often have tolerances of less than 5 µm, are challenging. Technological immanent process deviations obviate to manufacture components, meeting quality requirements at any time. Often cost-efficient realization of precision products is a conflict of objectives in the development, manufactur-ing and assembly process, saving production cost with high throughput under higher deviations on the one hand and preventing high number of scraped units with more narrow tolerances assuring the products func-tionality under higher capabilities on the other one. Even technological limits of the manufacturing processes are reached, producing cutting-edge products. In general, there are two approaches to cope with this challenge: an adaptive allocation of the tolerances by the product designer or an adaptive choice of the production strategy by the production planner. Both approaches provide fundamental concepts for producers in the market competition of producing economic quality precision products, which have not been systematically analysed in combination.

Approach: A new holistic approach of tolerance allocation and adaptive production strategies will be devel-oped, assessing technical and economic valuation of the product. The approach brings the engineering design requirements, product performance indicators, probabilistic manufacturing and assembly deviations and inspection uncertainties together in a common model, where the effects of adaptive tolerancing and adaptive production strategies on design, manufacturing, assembly and product function performances can be evaluated quantitatively. Adaptive tolerancing serves to allocate optimal characteristic tolerances under holistic technical and economic aspects. Adaptive production strategies take use of individual real-time assessment in cyber-physical produc-tion systems, compensating component deviations with over-fulfilment of an associated component. Thus, more narrow tolerance margins can be realized, meeting the quality requirements. The development of a functional product model enables detailed product knowledge integration into the afore-mentioned strategies. Quantitative dependencies on manufacturing deviations affecting the products functional fulfilment are contained to assess the introduced strategies on technical and economic aspects.

Result: The first results focus on the development and the comparison of meta-models: the developmet of a meta model correlating manufacturing deviations to the degree of functional fulfilment for the selected use case of spur and crown wheel micro-gears

Proof on the developed methodology in quality increase and cost-efficiency will be conducted on an exemplarily industrial application. Micro gears for dental instruments serve as an exemplarily demonstration, including numerous high quality requirements and complex characteristic interactions. Thus, the transferability and general applicability of developed methodologies on further use cases is assured.

The COVID crisis has an impact on the scientific production.

Motivation: Key functions of complex products often can only be realized by precision component use. Thus, producers are confronted with high quality requirements, cost pressure and a rising number of product variants. Especially, micro components, which often have tolerances of less than 5 µm, are challenging. Technological immanent process deviations obviate to manufacture components, meeting quality requirements at any time. Often cost-efficient realization of precision products is a conflict of objectives in the development, manufactur-ing and assembly process, saving production cost with high throughput under higher deviations on the one hand and preventing high number of scraped units with more narrow tolerances assuring the products func-tionality under higher capabilities on the other one. Even technological limits of the manufacturing processes are reached, producing cutting-edge products. In general, there are two approaches to cope with this challenge: an adaptive allocation of the tolerances by the product designer or an adaptive choice of the production strategy by the production planner. Both approaches provide fundamental concepts for producers in the market competition of producing economic quality precision products, which have not been systematically analysed in combination.

Approach: A new holistic approach of tolerance allocation and adaptive production strategies will be devel-oped, assessing technical and economic valuation of the product. The approach brings the engineering design requirements, product performance indicators, probabilistic manufacturing and assembly deviations and inspection uncertainties together in a common model, where the effects of adaptive tolerancing and adaptive production strategies on design, manufacturing, assembly and product function performances can be evaluated quantitatively. Adaptive tolerancing serves to allocate optimal characteristic tolerances under holistic technical and economic aspects. Adaptive production strategies take use of individual real-time assessment in cyber-physical produc-tion systems, compensating component deviations with over-fulfilment of an associated component. Thus, more narrow tolerance margins can be realized, meeting the quality requirements. The development of a functional product model enables detailed product knowledge integration into the afore-mentioned strategies. Quantitative dependencies on manufacturing deviations affecting the products functional fulfilment are contained to assess the introduced strategies on technical and economic aspects.

Result: Proof on the developed methodology in quality increase and cost-efficiency will be conducted on an exemplarily industrial application. Micro gears for dental instruments serve as an exemplarily demonstration,
including numerous high quality requirements and complex characteristic interactions. Thus, the transferability and general applicability of developed methodologies on further use cases is assured.

Project coordination

Jean-Yves DANTAN (Ecole Nationale Supérieure d'Arts et Métiers - Laboratoire Conception Fabrication Commande)

The author of this summary is the project coordinator, who is responsible for the content of this summary. The ANR declines any responsibility as for its contents.

Partner

KIT / WBK Karlsruhe Institute for Technology
ENSAM - LCFC Ecole Nationale Supérieure d'Arts et Métiers - Laboratoire Conception Fabrication Commande

Help of the ANR 268,920 euros
Beginning and duration of the scientific project: January 2020 - 36 Months

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